OPERATOR'S CAB

PART NO. 1703702 0100 SRM 1390

 SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and
that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to
support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift
trucks. Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT
TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use HYSTER ® APPROVED parts when making repairs. Replacement parts must meet or
exceed the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to
remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit
needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are
flammable. Be sure to follow the necessary safety precautions when handling these fuels and when
working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the
area. Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this
manual:

WARNING
Indicates a hazardous situation which, if not avoided, could result in death
or serious injury.

CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor
or moderate injury and property damage.
On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.
 Table of Contents

TABLE OF CONTENTS
Series Code / Model Designation Reference Table ................................................................................................ 1
General .....................................................................................................................................................................2
Description of Operation .........................................................................................................................................4
Cab Structure ...................................................................................................................................................... 4
Cab Tilt System ................................................................................................................................................... 4
Cab Tip-Up System ............................................................................................................................................. 6
Tilting the Cab .....................................................................................................................................................7
Raising ............................................................................................................................................................. 7
Lowering .......................................................................................................................................................... 8
Remove and Install ..................................................................................................................................................9
Cab Door Assembly ............................................................................................................................................. 9
Cab Door ...........................................................................................................................................................9
Remove ......................................................................................................................................................... 9
Install ........................................................................................................................................................... 9
Door Hinge ..................................................................................................................................................... 10
Remove ....................................................................................................................................................... 10
Install ......................................................................................................................................................... 10
Door Latch ......................................................................................................................................................11
Remove ....................................................................................................................................................... 11
Install ......................................................................................................................................................... 11
Door Handle ...................................................................................................................................................11
Remove ....................................................................................................................................................... 11
Install ......................................................................................................................................................... 12
Door Release .................................................................................................................................................. 12
Remove ....................................................................................................................................................... 12
Install ......................................................................................................................................................... 12
Door Push Button .......................................................................................................................................... 13
Remove ....................................................................................................................................................... 13
Install ......................................................................................................................................................... 13
Cab Tilt System ................................................................................................................................................. 13
Electric Tilt Pump ......................................................................................................................................... 13
Remove ....................................................................................................................................................... 13
Install ......................................................................................................................................................... 13
Hand Tilt Pump .............................................................................................................................................14
Remove ....................................................................................................................................................... 14
Install ......................................................................................................................................................... 15
Cab Tilt Cylinder ........................................................................................................................................... 16
Remove ....................................................................................................................................................... 16
Disassemble ............................................................................................................................................... 16
Clean ...........................................................................................................................................................18
Inspect ........................................................................................................................................................ 18
Assemble .................................................................................................................................................... 18
Install ......................................................................................................................................................... 19
Latch ...............................................................................................................................................................19
Remove ....................................................................................................................................................... 19
Install ......................................................................................................................................................... 20
Brake and Inching Pedal .................................................................................................................................. 21
Remove ........................................................................................................................................................... 21
Install ............................................................................................................................................................. 21
Accelerator Pedal and Sensor ........................................................................................................................... 22
Remove ........................................................................................................................................................... 22
Install ............................................................................................................................................................. 22

©2018 HYSTER COMPANY i

Table of Contents

TABLE OF CONTENTS (Continued)

Adjust Sensor .................................................................................................................................................22
Seat Assembly ....................................................................................................................................................22
Seat .................................................................................................................................................................22
Remove ....................................................................................................................................................... 22
Install ......................................................................................................................................................... 23
Seat Cushion ..................................................................................................................................................23
Remove ....................................................................................................................................................... 23
Install ......................................................................................................................................................... 24
Back Cushion ................................................................................................................................................. 24
Remove ....................................................................................................................................................... 24
Install ......................................................................................................................................................... 24
Seat Suspension Replacement ...................................................................................................................... 24
Boot Replacement ..........................................................................................................................................24
Suspension Scissor and Shock Absorber Replacement ............................................................................... 25
Remove ....................................................................................................................................................... 25
Install ......................................................................................................................................................... 30
Compressor .................................................................................................................................................... 37
Remove ....................................................................................................................................................... 37
Install ......................................................................................................................................................... 42
Power Assist Armrest ........................................................................................................................................48
Release Cable .................................................................................................................................................48
Remove ....................................................................................................................................................... 48
Install ......................................................................................................................................................... 48
Gas Spring ..................................................................................................................................................... 48
Remove ....................................................................................................................................................... 48
Install ......................................................................................................................................................... 49
Joystick .......................................................................................................................................................... 49
Remove ....................................................................................................................................................... 49
Install ......................................................................................................................................................... 49
Electrical Levers ............................................................................................................................................49
Remove ....................................................................................................................................................... 49
Install ......................................................................................................................................................... 50
Armrest Rocker Switches ..............................................................................................................................50
Remove ....................................................................................................................................................... 50
Install ......................................................................................................................................................... 50
Armrest Top Cover ........................................................................................................................................ 51
Remove ....................................................................................................................................................... 51
Install ......................................................................................................................................................... 51
Instrument Panel .............................................................................................................................................. 51
Key Switch ..................................................................................................................................................... 51
Remove ....................................................................................................................................................... 51
Install ......................................................................................................................................................... 51
12V Power Socket .......................................................................................................................................... 52
Remove ....................................................................................................................................................... 52
Install ......................................................................................................................................................... 52
Electric-Operated Heat Control and Air Recirculation Control (Airco Only) ............................................ 52
Remove ....................................................................................................................................................... 52
Install ......................................................................................................................................................... 53
Cable-Operated Heater Control (Heater Only) ............................................................................................53
Remove ....................................................................................................................................................... 53
Install ......................................................................................................................................................... 54
Air Conditioning Switch Replacement ......................................................................................................... 54

ii
 Table of Contents

TABLE OF CONTENTS (Continued)

Instrument Panel Rocker Switches Replacement ....................................................................................... 54
Parking Brake Switch ................................................................................................................................... 54
Remove ....................................................................................................................................................... 54
Install ......................................................................................................................................................... 55
Indicator Display Replacement .....................................................................................................................55
Instrument Panel Top Console ..................................................................................................................... 55
Remove ....................................................................................................................................................... 55
Install ......................................................................................................................................................... 56
Steering Wheel and Column Assembly ............................................................................................................ 56
Steering Wheel and Horn ..............................................................................................................................56
Remove ....................................................................................................................................................... 56
Install ......................................................................................................................................................... 58
Steering Column Assembly ...........................................................................................................................58
Remove ....................................................................................................................................................... 58
Install ......................................................................................................................................................... 59
Adjustment Handle ....................................................................................................................................... 60
Remove ....................................................................................................................................................... 60
Install ......................................................................................................................................................... 60
Main Warning Lights .................................................................................................................................... 60
Remove ....................................................................................................................................................... 60
Install ......................................................................................................................................................... 60
Shift Lever ..................................................................................................................................................... 60
Remove ....................................................................................................................................................... 60
Install ......................................................................................................................................................... 61
Turn Signal Lever ..........................................................................................................................................61
Remove ....................................................................................................................................................... 61
Install ......................................................................................................................................................... 61
Window Wipers ..................................................................................................................................................61
Window Wiper Assembly Replacement ........................................................................................................61
Remove ....................................................................................................................................................... 61
Install ......................................................................................................................................................... 61
Window Wiper Motor Replacement ..............................................................................................................62
Front Window Wiper Motor ...................................................................................................................... 62
Install ......................................................................................................................................................... 62
Rear Window Wiper Motor Assembly .......................................................................................................... 62
Remove ....................................................................................................................................................... 62
Install ......................................................................................................................................................... 62
Top Window Wiper Motor Assembly ............................................................................................................ 63
Remove ....................................................................................................................................................... 63
Install ......................................................................................................................................................... 63
Window Washer System ................................................................................................................................... 63
Window Washer Reservoir and Pumps ........................................................................................................ 63
Remove ....................................................................................................................................................... 63
Install ......................................................................................................................................................... 64
Window Washer Hoses ..................................................................................................................................64
Hoses for Top and Rear Window ...............................................................................................................64
Install ......................................................................................................................................................... 65
Window Washer Spray Nozzles ........................................................................................................................ 66
Front Window ................................................................................................................................................ 66
Remove ....................................................................................................................................................... 66
Install ......................................................................................................................................................... 66
Rear Window ..................................................................................................................................................66

iii
Table of Contents

TABLE OF CONTENTS (Continued)

Remove ....................................................................................................................................................... 66
Install ......................................................................................................................................................... 66
Top Window ................................................................................................................................................... 66
Remove ....................................................................................................................................................... 66
Install ......................................................................................................................................................... 67
Window Replacement ........................................................................................................................................67
Front Window ................................................................................................................................................ 69
Remove ....................................................................................................................................................... 69
Install ......................................................................................................................................................... 69
Rear Window ..................................................................................................................................................69
Remove ....................................................................................................................................................... 69
Install ......................................................................................................................................................... 69
Top Window ................................................................................................................................................... 70
Remove ....................................................................................................................................................... 70
Install ......................................................................................................................................................... 71
Door, Upper/Lower Window ..........................................................................................................................71
Remove ....................................................................................................................................................... 71
Install ......................................................................................................................................................... 71
Sliding Window and Sliding Tracks ............................................................................................................. 71
Remove ....................................................................................................................................................... 71
Install ......................................................................................................................................................... 73
Weather Strip Replacement ..........................................................................................................................73
Window Stopper Replacement ...................................................................................................................... 74
Window Seal Replacement ............................................................................................................................74
Sliding Window Frame ..................................................................................................................................74
Remove ....................................................................................................................................................... 74
Install ......................................................................................................................................................... 74
Floor Mat ........................................................................................................................................................... 75
Front Floor Mat ............................................................................................................................................. 75
Remove ....................................................................................................................................................... 75
Install ......................................................................................................................................................... 75
Rear Floor Mat ...............................................................................................................................................75
Remove ....................................................................................................................................................... 75
Install ......................................................................................................................................................... 76
Radio Console .................................................................................................................................................... 76
Remove ........................................................................................................................................................... 76
Install ............................................................................................................................................................. 77
Air Duct Replacement ....................................................................................................................................... 77
Remove Front .................................................................................................................................................77
Remove Rear .................................................................................................................................................. 77
Install ............................................................................................................................................................. 78
Accessories ......................................................................................................................................................... 79
Mirror Replacement ...................................................................................................................................... 79
Sunshade Replacement ................................................................................................................................. 79
Top .............................................................................................................................................................. 79
Rear ............................................................................................................................................................ 79
Map Light Replacement ................................................................................................................................ 79
Interior Fan Replacement .............................................................................................................................79
Training Seat ................................................................................................................................................. 80
Field Installation ....................................................................................................................................... 80
Remove ....................................................................................................................................................... 80
Label Replacement ............................................................................................................................................ 80

iv
 Table of Contents

TABLE OF CONTENTS (Continued)

Checks and Adjustments ...................................................................................................................................... 80
Check Oil Level for Cab Tilt System ................................................................................................................ 80
Door Striker Pin Adjustment ............................................................................................................................81
Brake Pedal Adjustment ...................................................................................................................................82
Dry Brake .......................................................................................................................................................82
Wet Brake ...................................................................................................................................................... 82
Inching Pedal Adjustment ................................................................................................................................ 82
Inching Pedal Sensor Adjustment .................................................................................................................... 83
Sensor Adjustment Using Dana Dashboard Software ................................................................................ 83
Sensor Adjustment using the APC200 Display ........................................................................................... 84
Sensor Adjustment for Trucks with ZF Transmission ................................................................................ 84
Inching Pedal Sensor Calibration .....................................................................................................................84
Sensor Calibration using Dana Dashboard Software ..................................................................................84
Sensor Calibration using APC200 Display .................................................................................................. 85
Sensor Calibration for Trucks with ZF Transmission .................................................................................85

This section is for the following models:

v
"THE
QUALITY
KEEPERS"

HYSTER
APPROVED
PARTS
0100 SRM 1390 Series Code / Model Designation Reference Table

Series Code / Model Designation Reference Table

This table consist of the following Series Codes used
in this manual.

Series European Model Americas Model

Code
A236 H16.00XM-12, H18.00XM-12, H20.00XM-12, H400HD, H450HD, H500HD,
H22.00XM-12 H550HD
A238 H16.00XM-9, H18.00XM-7.5, H16.00XM-12, H18.00XM-9 H360-36HD, H360-48HD
A917 H40.00-48.00XM-12, H36.00XMS-12 H800-1050HD/HDS
B214 H16.00-22.00XM-12EC H400-500HD/HDS-EC
B222 RS45-27CH, RS45-31CH, RS46-36CH, RS46-40CH, HR45-27, HR45-31, HR45-36,
RS46-41S CH, RS45-41L CH, RS46-41LS CH, RS45-24IH, HR45-40, HR45-41S, HR45-41L,
RS45-28IH, RS46-33IH, RS46-37IH, RS46-38S IH, HR45-41LS
RS46-38L IH, RS46-38LS IH
B236 H16.00XM-12, H18.00XM-12, H20.00XM-12, H400HD, H450HD, H500HD,
H22.00XM-12 H550HD
B238 H16.00XM-9, H18.00XM-7.5, H16.00XM-12, H18.00XM-9 H360-36HD, H360-48HD
B917 H36.00XMS-12 , H40.00XM-12, H44XM-12, H48.00XM-12 H800HD, H1050HD
C214 H16.00-12EC, H18XM-12EC, H22.00XM-12EC H400HD-EC, H450HD-EC,
H500HD-EC
C222 RS45-27CH, RS45-31CH, RS46-36CH, RS46-41L CH, RS45-27, RS45-31, RS45-36,
RS46-41S CH, RS46-41LS CH, RS45-24IH, RS45-28IH, RS46-41L, RS46-41S, RS46-41LS,,
RS46-33IH, RS46-38L IH, RS46-38S IH, RS46-38LS IH
C236 H18-20XM-9, HS18-20XMS-9 H400HD, H450HD, H400HDS,
H450HDS
C917 H40XMS-12, H44XM-12, H48XM-12, H36XMS-12, H800HDS, H900HDS, H970HDS,
H40XMS-12, H44XMS-12, H48XMS-12 H1050HDS
H900HD, H970HD, H1050HD
D214 H18XM-12EC, H22XM-12EC, H23XN-12EC H450HD-EC, H500HD-EC
D222 RS45-27CH, RS45-31CH, RS46-36CH, RS46-41L CH, RS45-27CH, RS45-31CH,
RS46-41S CH, RS46-41LS CH, RS46-33IH, RS46-38LS RS46-36CH, RS46-41L CH,
IH, RS46-41S CH, RS46-41LS CH
RS46-38S IH, RS46-38LS IH
E019 H13.00-16.00XM, H10.00-12.00XM-12EC H300-360HD, H360HD-EC
E117 H40.00-52.00XM-16CH H1050HD-CH, H1150HD-CH
F007 H8.00-12.00XM J170-280HD
F008 H25-32XM-12, H28-16CH, H32XM-16CH, H550-700HD, H550-700HDS
H25-32XMS-9
F019, G019 H13.00-14.00XM, H16.00XM-6, H10.00-12.00XM-12EC H300-330HD, H360HD, H360HD-
EC
F117 H40.00-52.00XM-16CH H1050HD-CH, H1150HD-CH

1
General 0100 SRM 1390

Series European Model Americas Model

Code
G007, H007 H8.00-12.00XM J170-280HD
G008 H25-32XM-12, H25-32XMS-9 H550-700HD, H550-700HDS
G117 H40.00-52.00XM-16CH H1050HD-CH, H1150HD-CH
H008 H25-32XM-12, H25-32XMS-9, H28-32XM-16CH H550-700HD, H550-700HDS
H019 H13.00-16.00XM-6, H10.00-12.00XM-12EC H300-360HD2, H360HD2-EC
H117 H40.00-52.00XM-16CH H1050HD-16CH, H1150HD-16CH
J007 H8-10XM-6, H10-12XMS-6 J190-280HD2
J019 H13-16XM-6, H10-12XM-12EC H300-360HD2, H360HD2-EC
J117 H40.00-52.00XM-16CH H1050HD-16CH, H1150HD-16CH
K007 H8-12XM-6, H10XMS-6 J190-280HD2, H230HDS
K019 H13-16XM-6 H210-250-48HD2, H300-360HD2
K019EC H6-7XM-12EC H360HD2-EC
L007 H8-12XM-6 H190-280HD2, H250HD2

General
This SRM describes the functions of the cab and components are options that may not be present on
the replacement instructions for the cab each cab. The operation of the various switches and
components. See Figure 1. Some of the described controls can be found in the Operating Manual.

2
0100 SRM 1390 General

Figure 1. Operator's Cab

3
Description of Operation
Legend for Figure 1.
1. HEATER SECTION
2. INCHING PEDAL
3. BRAKE PEDAL
4. ACCELERATOR PEDAL
5. STEERING COLUMN
6. FRONT, REAR, AND TOP WINDOWS
The description and repair instructions for the
heater and air conditioner are in the following Cab
Heater manuals:
Cab Heater (Prior to Oct. 2008)
•
0100SRM1458
• Cab Heater/Air Conditioning (October,
2008 - October, 2017) 0100SRM1459
• Cab Heater/Air Conditioning (After
October, 2017) 0100SRM2107
The remove and replace instructions for the cab as
an assembly are in the frame SRM specific to each
model lift truck.
Description of Operation
CAB STRUCTURE
The cab frame is a welded structure. The overhead
guard is an integral part of the cab frame. See
Figure 1. In order to maintain maximum overhead
protection, changes to the cab frame and integrated
overhead guard are not allowed. There are two cab
options: an open cab and a closed cab. The closed
cab features windows and wipers, doors, a heater,
and optional air conditioning. Both cab types
feature interior components.
CAB TILT SYSTEM
On lift trucks with a cab tilt system, the cab can tilt
to the right-hand side, providing service access to
the engine compartment and components under the
cab.
The cab tilt system consists of a cab support frame,
cab tilt cylinder, cab tilt hand pump assembly, cab
latches, and an optional electrical cab tilt pump. See
Figure 2.
The cab is attached to the lift truck in the lowered
position by the cab support pivots on the right-hand
frame channel, the two cab latches on the left-hand
frame channel, and the cab tilt cylinder.
Hydraulic pressure is required to unlock the cab
latches and extend the cab tilt cylinder. The cab can
4
0100 SRM 1390
7. FRONT, REAR, AND TOP WIPER ASSEMBLIES
8. INTEGRATED OVERHEAD GUARD
9. OPERATOR'S CONSOLE, CONTROLS, AND
ARMREST
10. AIR CONDITIONING CONDENSER, DRYER, AND
FAN ASSEMBLY (OPTIONAL)
11. SEAT
Information on systems that are related to the cab
are in SRM for the Electrical System, Hydraulic
System, Brake System, Steering System and
Diagrams specific to each model lift truck.
Before making any repairs to the lift truck,
complete the following procedures:
1. Place the lift truck on a solid, level surface.
2. Lower the mast completely and tilt forward.
3. Place the shift lever in NEUTRAL.
4. Apply the parking brake.
5. Shut down the engine.
be raised by rotating the cab tilt hand pump
directional valve clockwise and operating the cab
tilt hand pump. See Figure 3. To lower the cab from
the raised position, rotate the cab tilt hand pump
directional valve counterclockwise and operate the
cab tilt hand pump. The cab tilt cylinder retracts to
lower the cab.
The optional electrical cab tilt pump is push-button
operated. See Figure 8.
NOTE: If the optional electrical cab tilt pump is
inoperable, the cab can be raised or lowered by
using the manually operated cab tilt hand pump.
When the cab has been raised to the partially open
position, a latch will engage with a retainer plate
that is welded to the frame. To raise or lower the
cab after the latch has engaged, pull and hold the
latch release handle and raise or lower the cab until
the latch has passed the retainer plate.
Just before the fully open position is reached,
movement becomes gravity-controlled by the weight
of the cab. The cab is in the fully open position when
the cab tilt cylinder is fully extended.
0100 SRM 1390 Description of Operation

When raising the cab, the directional valve is in the

raise position; the pump push port and pump pull
port are connected to each other. See Figure 4.
Hydraulic pressure is transferred to the cab latches
and both the piston and rod side of the cab tilt
cylinder. Hydraulic oil extruded at the rod side
enters the piston side of the cylinder through the
directional valve in the hand pump. The end of
stroke is determined by a retaining ring in the cab
tilt cylinder.
When lowering the cab, the directional valve is in
the lower position, the pump push port is connected
to the pump reservoir through a reservoir check
valve. The reservoir check valve retains enough
pressure to keep the cab locks open. The pump pull
port is connected to the hand pump. While the hand
pump provides sufficient pressure, the cylinder
check valve will raise to allow the oil at the piston
side of the cylinder to return to the reservoir. The
cylinder cannot lower when there is insufficient
pressure at the pull connection.
1. CAB SUPPORT FRAME
2. CAB TILT HAND PUMP When the piston has reached the free fall area, the
3. CAB LATCH oil at the piston side will escape to the rod side and
4. LATCH RELEASE HANDLE the cab will drop under the influence of its own
5. CAB TILT CYLINDER
6. LATCH weight. When the cab drops, the oil in the cab lock
7. RETAINER PLATE cylinders is pushed out through the reservoir check
valve. After the cab has dropped, the cab is locked
Figure 2. Cab Tilt System into position by the cab latches.

A. LOWER POSITION
B. RAISE POSITION

1. PUMP LEVER CONNECTION

2. PUMP DIRECTIONAL VALVE

Figure 3. Cab Tilt Hand Pump

5
Description of Operation 0100 SRM 1390

1. ROD AREA 9. CAB TILT HAND PUMP

2. CAB TILT CYLINDER 10. RESERVOIR CHECK VALVE
3. FREE FALL INTERCONNECTION 11. LOWER POSITION
4. CHECK VALVE 12. PUMP DIRECTIONAL VALVE
5. PULL-PORT 13. RAISE POSITION
6. ELECTRIC CAB TILT PUMP (OPTIONAL) 14. LATCH
7. RESERVOIR 15. PUSH-PORT
8. RELIEF VALVE

Figure 4. Cab Tilt System

CAB TIP-UP SYSTEM the cab raises or lowers depending on signals from
the height sensor, which is installed at the back-side
Additional to the cab tilt system, a cab tip-up of the mast. See Figure 6.
system can be installed. The cab tip-up system lets
the cab tip up to 10° and down. This can be
controlled by moving the cab up and down, or
automatically by following the load, depending on
the height of the load, controlled by a height sensor.
The cab tip-up system consists of an additional
support frame, mounted on the cab support frame,
catch security brackets and actuators. See Figure 5.
The cab tip-up system can have three states, OFF,
ON and AUTO. In the ON state the cab can be
raised and lowered manually, in the AUTO state

6
0100 SRM 1390 Description of Operation

WARNING
Make sure no one and no body parts are under the
cab when raising or lowering the cab, or serious
personal injury may occur.

WARNING
Before doing any work under the cab, always make
sure the cab is fully tilted/raised, or if partially
open, is locked with the tilt latch, or serious
personal injury may occur.

CAUTION
Cab damage may occur if the mast is not
completely tilted forward.

1. Tilt the mast fully forward.

Figure 5. Cab Tip-up Actuators
2. Put the ignition switch in the OFF position.

3. Apply the park brake.

4. Remove all unsecured items from the cab.

5. Close and securely latch the left-hand and

right-hand cab doors.

6. Clear all obstacles from the right-hand side of

the lift truck. Provide a minimum of 2 m (7 ft)
clearance space.

7. Use the pump lever to turn the pump

directional valve clockwise to the "Tilt/Raise"
position. See Figure 7.

Figure 6. Cab Tip-up Sensor

TILTING THE CAB

Raising
NOTE: If the cab will not fully tilt/raise, lower the
cab until the cab locks in the partially open position,
and check the oil level in the pump. Refer to the
section Oil Filling for Cab Tilt System.

7
Description of Operation 0100 SRM 1390

1. CAB
A. LOWER POSITION 2. FRAME
B. RAISE POSITION 3. TILT LATCH RELEASE HANDLE
4. ELECTRIC CAB TILT PUSH-BUTTON
1. PUMP LEVER CONNECTION (OPTIONAL)
2. PUMP DIRECTIONAL VALVE 5. PUMP LEVER
Figure 7. Pump and Direction Valve Figure 8. Pump Lever and Tilt Latch Release
Handle
8. Operate the pump with the pump lever (or
push-button, if equipped with an electric Lowering
pump), until the cab locks in the partially open
position. See Figure 8.
WARNING
NOTE: Just before the fully open position is Make sure no one is under the cab when raising or
reached, movement becomes gravity-controlled by lowering the cab, or serious personal injury may
the weight of the cab. occur.
9. Pull the latch release handle and continue to
tilt/ raise the cab to the fully open position. See
Figure 8. WARNING
Before doing any work under the cab, always make
sure the cab is fully tilted/raised, or if partially
open, is locked with the tilt latch, or serious
personal injury may occur.

CAUTION
Cab damage may occur if the mast is not
completely tilted forward.

1. Make sure all foreign items/tools are removed

from under the cab.

2. Use the pump lever to turn the pump

directional valve counterclockwise to the
"Lower" position. See Figure Figure 7.

8
0100 SRM 1390 Remove and Install

3. Operate the pump with the pump lever (or 4. Pull the tilt latch release handle and continue
push-button, if equipped), until the cab locks in to lower the cab until the cab is in the fully
the partially open position. See Figure 8. lowered and latched position.

Remove and Install

CAB DOOR ASSEMBLY
Cab Door
Remove
1. Open the sliding windows.

2. Attach a lift strap at the left-hand and right-

hand side of the sliding windows inside the
sliding window frame. Place a cushion between
the sliding window frame and the lift straps
(left-hand and right-hand sides) to prevent
damage.

3. Position the cab door at a 90° angle to the

frame, so the cab door can be lifted out the
hinges.

CAUTION
Use caution when lifting the cab door to avoid
damage to the cab frame.

4. Lift the cab door out of the cab door hinges. See
Figure 9.

A. VIEW TURNED 90° COUNTERCLOCKWISE

1. DOOR HINGE
2. DOOR PUSH-BUTTON
3. DOOR RELEASE
4. DOOR LATCH
5. DOOR HANDLE

Figure 9. Cab Door

5. Move the cab door away from the lift truck and
place it on the ground.

6. Close the sliding windows.

Install
1. Open the sliding windows.

9
Remove and Install 0100 SRM 1390

2. Attach a lift strap to the left-hand and right-

hand side of the sliding windows inside the
sliding window frame. Place a cushion between
the sliding window frame and the lift straps
(left-hand and right-hand sides) to prevent
damage.

3. Raise the cab door and place it in position

above the hinges.

4. Slowly lower the cab door until the cab door is

seated on the hinges.

5. Remove the lift strap.

6. Make sure the cab door is opening, closing, and

moving properly on the hinges.

7. Make sure the locking system functions

properly.

NOTE: Adjust one hinge at a time.

8. If necessary, adjust the hinge location when the
door is closed. Door clearance must be evenly
divided around the door and door opening of
the cab.

9. Loosen the three capscrews and use a nylon

hammer to adjust the hinge. Retighten the
capscrews.

10. If necessary, adjust the door striker pin. Refer

to the section Door Striker Pin Adjustment.

Door Hinge
Remove
1. Remove the cab door. See the section Cab Door.
1. DOOR HINGE 3. CAB FRAME
2. CAPSCREW
2. Mark the location of the two hinges on the cab
frame. Figure 10. Door Hinge
3. Remove the six capscrews retaining the two Install
hinges to the cab frame and remove the two
hinges. See Figure 10. 1. Position the two hinges to the cab frame as
marked and install the six capscrews to retain
the hinges to the cab frame.

2. Install the cab door. Refer to the section Cab

Door.

3. Make sure the locking system functions

properly.

10
0100 SRM 1390 Remove and Install

NOTE: Adjust one hinge at a time. 3. Install the capscrew and washer that retain the
plastic cover to the door latch.
4. If necessary, adjust the hinge location when the
door is closed.
4. Make sure the locking system functions
correctly.
5. Loosen the three capscrews and use a nylon
hammer to adjust the hinge. Retighten the
capscrews. Door Handle
Remove
Door Latch
1. Remove the door latch. Refer to the section
Remove Door Latch.
1. Remove the capscrew and washer that retain
2. Remove the plastic plug at the inside of the
the plastic cover to the door latch. See
door frame. See Figure 12.
Figure 11.

1. CAPSCREW
2. WASHER 1. WASHER
3. PLASTIC COVER 2. CAPSCREW
4. CAPSCREW 3. PLASTIC PLUG
5. DOOR LATCH 4. CAB DOOR
6. CAB DOOR 5. RUBBER CUSHION (LARGE)
7. CONNECTOR ROD 6. DOOR HANDLE
7. RUBBER CUSHION (SMALL)
Figure 11. Door Latch
Figure 12. Door Handle
2. Remove the two capscrews that retain the door
latch to the door frame. 3. Remove the capscrew and washer that retain
the door handle, through the hole from the
3. Disconnect the connector rod from the door plastic plug.
latch attached to the door release.
4. Remove the large nut and washer that retain
Install the door handle on the release button side of
the door handle.
1. Connect the connector rod to the door latch
attached to the door release. 5. Remove the door handle and two rubber
cushions.
2. Install the two capscrews to retain the door
latch to the door frame.

11
Remove and Install 0100 SRM 1390

Install
1. Position the door handle and two rubber
cushions on the door. See Figure 12.

2. Install the washer and large nut on the release

button side of the door handle.

3. Install the washer and capscrew through the

hole from the plastic plug.

4. Install the plastic plug at the inside of the door

frame.

5. Install the latch. Refer to the section Door

Latch.

6. Make sure the locking system functions

correctly.

Door Release
Remove
1. Remove the door latch. Refer to the section
Door Latch.
1. CAPSCREW
2. DOOR RELEASE
2. Remove the capscrew that retains the door 3. CONNECTOR ROD
release inside the bar located at the inside of 4. CAB DOOR
the door frame. See Figure 13.
Figure 13. Door Release

3. Remove the connector rod and door release

from inside the bar.

4. Disconnect the connector rod from the door

release.

Install
1. Connect the connector rod to the door release.
See Figure 13.

2. Install the connector and door release inside

the bar, located at the inside of the door frame.

3. Install the capscrew that retains the door

release inside the bar.

4. Install the door latch. Refer to the section Door

Latch.

12
0100 SRM 1390 Remove and Install

Door Push Button CAB TILT SYSTEM

Remove Electric Tilt Pump
1. Remove the three plastic caps from the nuts Remove
located at the inside of the door frame. See
Figure 14. 1. Tilt/raise the cab to the fully open position.
Refer to the section Tilting the Cab.

2. Disconnect the electrical connector, located at

the left-hand panel, from the cab tilt push-
button. See Tilting the Cab and Figure 8.

3. Remove the two capscrews and washers that

retain the left-hand panel to the frame and
remove the left-hand panel.

4. Disconnect the electrical connector from the

electrical tilt pump.

5. Tag and disconnect the two hydraulic hoses

from the electrical tilt pump and place plugs on
the hose ends.

6. Remove the two nuts that retain the bracket

1. CAB DOOR with the electrical tilt pump to the frame.
2. WASHER
3. SEAL
4. DOOR HOLDER (PUSH BUTTON) 7. Remove the bracket with the electrical tilt
5. WASHER pump from the frame.
6. NUT
7. CAPSCREW 8. Remove the two capscrews that retain the
electrical tilt pump to the bracket.
Figure 14. Door Push Button
9. Remove the electrical tilt pump from the
2. Remove the three nuts, washers, and capscrews bracket.
that retain the door holder (push button),
washer, and seal to the door frame. Install
Install 1. Position the electrical tilt pump on the bracket.

1. Install the three capscrews, washers, and nuts
that retain the door holder (push button),
washer, and seal to the door frame. Hand
tighten the nuts. See Figure 14.
2. Position the cab door in the locking system.
3. Tighten the three nuts.
2. Install the two capscrews that retain the
electrical tilt pump on the bracket.
3. Position the bracket with the electrical tilt
pump on the frame.
4. Install the two nuts that retain the bracket
with the electrical tilt pump to the frame.

4. Make sure the door holder is positioned 5.
properly by placing the door in the lock system.
Adjust the door holder (push button) as needed.
6.
5. Install the three plastic caps to the nuts located
at the inside of the door frame.
Remove the plugs and connect the two hoses to
the electrical tilt pump.
Connect the electrical connector to the
electrical tilt pump.

13
Remove and Install
7. Position the left-hand panel on the frame and
install the two capscrews and washers to retain
the panel to the frame.
8. Connect the electrical connector to the cab tilt
push-button. See Tilting the Cab and Figure 8.
9. Lower the cab to the fully lowered and latched
position. Refer to the section Tilting the Cab.
10. Operate the electric tilt pump to check for leaks
and to remove air from the cab tilt system.
11. Check the hydraulic oil level. Refer to the
section Check Oil Level for Cab Tilt System.
12. Operate the cab tilt system to check for correct
operation.
14
0100 SRM 1390
Hand Tilt Pump
Remove
1. Tilt/raise the cab to the fully open position.
Refer to the section Tilting the Cab.
2. If equipped, disconnect the electrical connector
located at the left-hand panel, from the cab tilt
push-button. See Tilting the Cab and Figure 8.
3. Remove the two capscrews and washers that
retain the left-hand panel to the frame and
remove the left-hand panel.
4. Remove the two capscrews and washers that
retain the hand pump to the frame. See
Figure 15.
0100 SRM 1390 Remove and Install

A. 180 DEGREES TURNED

1. FRAME 4. WASHER
2. HAND PUMP 5. CAPSCREW
3. HYDRAULIC HOSE

Figure 15. Hand Pump

NOTE: Keep the hydraulic hose connection
locations from the hand pump facing upward to
avoid spilling hydraulic oil.
5. Tag and disconnect the three hydraulic hoses
and place plugs on the three hose ends. See
Figure 15.
Install
1. Remove the plugs from the three hose ends and
connect the three hydraulic hoses to the hand
pump. See Figure 15.
2. Position the hand pump on the frame and
install the two capscrews and washers that
retain the hand pump to the frame. See
Figure 15.
3. Position the left-hand panel to the frame and
install the two capscrews and washers to retain
the left-hand panel to the frame.
4. If equipped, connect the electrical connector to
the cab tilt push-button. See Tilting the Cab
and Figure 8.

5. Lower the cab to the fully lowered and latched

position. Refer to the section Tilting the Cab.

15
Remove and Install 0100 SRM 1390

6. Remove the fill cap of the hand pump and fill

the reservoir with hydraulic oil. Refer to the
section Check Oil Level for Cab Tilt System.

7. Make sure the cab tilt system functions

correctly.

Cab Tilt Cylinder

Remove
1. Tilt/raise the cab until it locks in the partially
open position. Refer to the section Tilting the
Cab.

2. Place wooden blocks between the frame and the

cab to prevent the cab from suddenly lowering.

3. Tag and disconnect the two hydraulic hoses

from the cab tilt cylinder and install caps on
the hydraulic fittings and plugs in the
hydraulic hoses. See Figure 17.

4. Remove the snap ring from the pin that retains

the cab tilt cylinder to the frame. See
Figure 16.

1. CAB TILT FRAME

2. SNAP RING
3. CAB TILT CYLINDER
4. PIN
5. FRAME

Figure 16. Cab Tilt Cylinder

5. Remove the snap ring from the pin that retains

the cab tilt cylinder to the cab tilt frame.

6. Remove the cab tilt cylinder from the pins and

remove the cab tilt cylinder from under the
frame.

Disassemble
1. Place the cab tilt cylinder in a horizontal
position with the fittings pointing downward in
a vise with soft jaws.

16
0100 SRM 1390 Remove and Install

2. Place a drain pan under the fittings.

3. Remove the caps from the fittings and drain

the hydraulic oil from the cab tilt cylinder.

4. Remove the wiper from the cylinder shell. See

Figure 17.

1. FILTER 11. O-RING

2. HYDRAULIC 12. O-RING
FITTINGS 13. SLEEVE
3. SPACER 14. PISTON
4. WIPER 15. WASHER
5. GLAND RETAINING 16. O-RING
RING 17. CHECK VALVE
6. U-CUP ASSEMBLY
7. O-RING 18. PILOT PISTON
8. GLAND ASSEMBLY
9. END OF STROKE 19. O-RING
RING
10. SHAFT RETAINING
RING

Figure 17. Cab Tilt Cylinder

17
Remove and Install
5. Press the gland inside the cylinder shell until
the gland retaining ring is free.
6. Remove the gland retaining ring.
CAUTION
Be careful not to damage the finished surface of
the piston rod when removing the piston rod
assembly from the cylinder shell in a horizontal
position.
7. Remove the piston rod assembly from the
cylinder shell by pulling it out of the cylinder
shell.
CAUTION
Be careful not to damage the grooves when
removing O-rings, sleeve, U-cup, and retaining
rings.
8. Remove the shaft retaining ring that retains
the piston to the piston rod. See Figure 17.
9. Remove the piston from the piston rod.
10. Remove the end of stroke ring from the piston
rod. See Figure 17.
11. Remove the gland from the piston rod.
12. Remove and discard the O-ring from the piston
rod.
13. Remove and discard the O-ring and sleeve from
the piston.
14. Remove and discard the O-ring and U-cup from
the gland.
15. Use a special tool to remove the check valve
assembly, located inside the cylinder shell.
16. Remove and discard the pilot piston assembly,
located inside the cylinder shell.
18
0100 SRM 1390
Clean
WARNING
Cleaning solvents can be flammable and toxic and
can cause skin irritation. When using cleaning
solvents, always follow the solvent manufacturer’s
recommended safety procedures.
Compressed air can move particles so they cause
injury to the user or to other personnel. Make sure
that the path of the compressed air is away from
all personnel. Wear protective goggles or a face
shield to prevent injury to the eyes.
Clean all parts in solvent and dry with compressed
air.
Inspect
Inspect the parts of the cab tilt cylinder for damage,
rust, or wear. Carefully inspect the rod surface for
dents and scratches. Make sure that the internal
stroke surface of the cylinder shell and grooves for
the seals do not show any nicks, scratches, or other
damage. Repair or replace parts as needed.
Assemble
NOTE: Make sure that all parts are clean before
assembly.
NOTE: Always use new O-rings, sleeve, and U-cup.
Lubricate all parts with clean hydraulic oil.
1. Install the new pilot piston assembly, located
inside the cylinder shell.
2. Use a special tool to install the check valve
assembly into the cylinder shell and tighten to
40 to 45 N•m (30 to 33 lbf ft).
3. Install a new O-ring and U-cup to the gland.
4. Install a new O-ring and sleeve on the piston.
5. Install a new O-ring on the piston rod.
6. Assemble the gland on the piston rod.
7. Install the end of stroke ring on the piston rod.
See Figure 17.
8. Install the piston on the piston rod.
9. Install the shaft retaining ring that retains the
piston to the piston rod. See Figure 17.
0100 SRM 1390 Remove and Install

5. Remove the caps and plugs from the cab tilt

CAUTION
Be careful not to damage the finished surface of
the piston rod when installing the piston rod
assembly into the cylinder shell in a horizontal
position.
10. Lubricate the cylinder shell bore with clean
hydraulic oil. Place the piston rod assembly
into the cylinder shell.
11. Press the gland inside the cylinder shell until
the groove for the gland retaining ring is free.
12. Install the gland retaining ring.
cylinder and hydraulic hoses and connect the
two hydraulic hoses to the cab tilt cylinder.
NOTE: If the oil level is low, the cab will not tilt/
raise completely. Refer to the section Check Oil
Level for Cab Tilt System.
6. Check the hydraulic oil level. Refer to the
section Check Oil Level for Cab Tilt System.
7. Completely tilt/raise the cab. Refer to the
section Tilting the Cab.
8. Remove the wooden blocks between the frame
and the cab.

13. Pressurize the push port until the extended rod 9. Lower the cab until it is in the fully lowered
locks the gland into the gland retaining ring. and latched position.

14. Install the wiper. 10. Operate the cab tilt system to check for leaks
and correct operation.
Install
1. Position the cab tilt cylinder inside the frame Latch
with the hydraulic hose fittings positioned to Remove
the underside.
1. Tilt/raise the cab until it locks in the partially
2. Install the cab tilt cylinder to the pin of the cab open position. Refer to the section Tilting the
tilt frame and the pin of the frame. Cab.

3. Install the snap ring to the pin that retains the 2. Disconnect the hydraulic hose from the front
cab tilt cylinder to the cab tilt frame. latch and plug the hose end. See Figure 18.

4. Install the snap ring to retain the cab tilt

cylinder to the frame.

19
Remove and Install 0100 SRM 1390

A. 180 DEGREES TURNED

1. FRONT LATCH 5. CAPSCREW

2. REAR LATCH 6. WASHER
3. FRAME 7. NUT
4. HYDRAULIC HOSE 8. T-ADAPTER

Figure 18. Latch

3. Remove the T-adapter from the rear latch and Install

place a cap at the T-adapter. See Figure 18.
1.
4. Remove the eight capscrews and nuts, and 16
washers that retain the front and rear latches
to the frame. See Figure 18.
Position the front and rear latches on the frame
and install the eight capscrews and nuts, and
16 washers to retain the front and rear latches
to the frame. See Figure 18.

2. Remove the cap at the T-adapter and install

the T-adapter to the rear latch. See Figure 18.

20
0100 SRM 1390 Remove and Install

3. Remove the plug from the hose end and connect

the hydraulic hose to the front latch. See
Figure 18.

4. If required, remove the fill cap of the hand

pump and fill the reservoir with hydraulic oil.
Refer to the section Check Oil Level for Cab
Tilt System.

5. Lower the cab until it is in the fully lowered

and latched position. Refer to the section
Tilting the Cab. Check the latches for correct
operation.

BRAKE AND INCHING PEDAL

Remove
1. Remove the split pin and washer from the rod,
located behind the inching pedal. See
Figure 19.

2. Disconnect the rod from the inching pedal.

1. BRAKE PEDAL
2. INCHING PEDAL
3. Remove the two capscrews, washers, and nuts 3. SPLIT PIN
that retain the inching pedal to the bracket at 4. ROD
the floor of the cab. 5. CAP SCREWS, WASHERS AND NUTS
6. BEARINGS
4. Remove the two capscrews, washers, and nuts 7. SHIMS
that retain the brake pedal to the bracket at
Figure 19. Brake and Inching Pedals Assembly
the floor of the cab.

5. Remove the inching and brake pedal assembly. Install

1. Install the two bearings on the inching pedal.
6. Separate the inching pedal from the brake See Figure 19.
pedal and remove the three shims.
NOTE: Make sure the three shims are positioned
7. Remove the two bearings from the inching correctly.
pedal.
2. Position the three shims and install the inching
pedal to the brake pedal.

3. Position the inching and brake pedal assembly

between the brackets at the floor of the cab.

4. Install the two capscrews, washers, and nuts

that retain the brake pedal to the bracket at
the floor of the cab.

5. Install the two capscrews, washers, and nuts

that retain the inching pedal to the bracket, at
the floor of the cab.

6. Connect the rod to the inching pedal.

21
Remove and Install 0100 SRM 1390

7. Install the washer and split pin to the rod,
located behind the inching pedal.
8. Check if adjustments to the inching and brake
pedals are required, and adjust as needed.
Refer to the sections Brake Pedal Adjustment
and Inching Pedal Adjustment.
ACCELERATOR PEDAL AND SENSOR
Remove
1. Remove the spring and capscrew on which the
pedal pivots. See Figure 20.
2. Turn the pedal 90 degrees and maneuver the
lower part of the pedal through the hole in the
floor plate into the cab.
2. Grease and install the bushing and pedal pivot
onto the capscrew. Position the end of the
sensor connecting rod into the pedal and fit the
assembly onto the mounting plate. Tighten the
nut. See Figure 20.
3. Fit the spring and check the adjustment of the
accelerator pedal sensor.
Adjust Sensor
1. Start the engine and verify that idle speed will
raise after the pedal has been depressed
between 6 and 10 mm (0.236 and 0.394 in.). See
Dimension A in Figure 20.
2. If adjustment is incorrect, raise the cab until it
rests in the partially open position. Refer to the
section Tilting the Cab.

3. Place a 5 mm (0.197 in.) spacer between the

pedal and the rubber pedal bumper.

4. Loosen the mounting screws of the pedal sensor

and turn the sensor until engine speed is about
to increase from idle.

5. Tighten the mounting screws and remove the

spacer between pedal and pedal bumper. Stop
the engine.

SEAT ASSEMBLY
Seat
Remove
NOTE: Use a lifting device for the removal of the
seat.
NOTE: The ground cable is attached with a
1. DIMENSION A capscrew at the right rear corner of the suspension.
2. ACCELERATOR PEDAL 1. Disconnect the battery ground cable.
3. ACCELERATOR PEDAL ADJUSTMENT
4. ACCELERATOR PEDAL SENSOR
5. MOUNTING SCREW NOTE: There is one electrical connector on the
6. CONNECTING ROD mechanical seat. There are two electrical connectors
7. CAB FLOOR PLATE on the air suspension seat.
8. ACCELERATOR PEDAL STOP
9. COUNTERCLOCKWISE 2. Disconnect the electrical connector(s).
10. SLOTTED HOLE
3. Turn the electrical plug counterclockwise and
Figure 20. Accelerator Arrangement disconnect the electrical plug located at the
instrument panel side console.
Install
1. Maneuver the lower part of the pedal from the
cab interior through the hole in the floor plate.

22
0100 SRM 1390 Remove and Install

NOTE: The seat must be positioned completely to
the front to allow access to the two front capscrews
inside the sliding system. The seat must be
positioned completely to the rear to allow access to
the two rear capscrews inside the sliding system.
4. Remove the four capscrews, washers, and nuts
located above the sliding system that retain the
seat to the seat suspension.
5. Remove the seat. See Figure 21.
2. Install the four capscrews, washers, and nuts
located above the sliding system that retain the
seat to the seat suspension.
3. Connect the electrical plug located at the
instrument panel side console.
NOTE: There is one electrical connector on the
mechanical seat. There are two electrical connectors
on the air suspension seat.
4. Connect the connector(s).

NOTE: The ground cable is attached with the

capscrew at the right rear corner of the suspension.
5. Connect the battery ground cable.

Seat Cushion
Remove
Refer to Figure 21 for the following procedures.

1. Slide the seat forward.

2. Adjust the steering wheel upward to its

maximum height position.

3. Remove and discard the screw from the front

right side.

4. Remove and discard the three clips from the

cushion front.

5. Slide the seat fully backward.

6. Grip the seat cushion on the front right corner.

1. SEAT CUSHION 7. Lift the seat cushion until the guide block
2. BACK CUSHION becomes detached.
3. BOOT
4. SEAT SUSPENSION 8. Rotate the seat cushion clockwise.

Figure 21. Seat
Install
NOTE: Use a lifting device to install the seat.
1. Position the seat onto the seat suspension.
NOTE: The seat must be positioned completely to
the front to allow access to the two front capscrews
inside the sliding system. The seat must be
positioned completely to the rear to allow access to
the two rear capscrews inside the sliding system.
9. Lift the cushion upward to detach the front of
the seat cushion.
10. Grip the seat cushion at about the halfway
point toward the rear of the cushion.
NOTE: Increase the lifting force until the rear of
the cushion detaches.
11. Lift the seat cushion from right to left.
12. Cut the cable tie securing the connector block
to the seat cushion.

23
Remove and Install 0100 SRM 1390

13. Disconnect the spade connectors from the 4. Remove the two screws that retain the back
connector block. cushion to the back pan.

14. Remove and discard the seat cushion. 5. Remove the back cushion.

Install Install
1. Feed the cables of the new cushion through the 1. Position the back cushion.
hole in the armrest bracket.
2. Install the two screws that retain the back
2. Connect the spade connectors to the connector cushion to the back pan.
block.
3. Install the two guides, located at the top side of
3. Use a cable tie to attach the connector block to the back cushion, that retain the back cushion
the seat cushion. to the back pan.

4. Locate the rear tab on the underside of the seat 4. If equipped, install the headrest in the two
cushion over the rectangular hole in the metal guides.
pan.
5. Reposition the seat assembly to the correct
5. Apply downward pressure over the tab. operating position.

6. Slide the cushion around until the tab is
partially located in the rectangular hole.
7. With the cushion angled at approximately 35°
to 45°, apply a sharp blow to the front of the
seat cushion. The tab will enter the hole with
an audible click.
8. Pull the cushion upward to make sure the
cushion is correctly locked into position.
9. Install three new clips to the cushion front.
10. Install a new screw to the front right side.
Seat Suspension Replacement
Refer to Figure 21 for the following procedures.
1. Remove the four capscrews that retain the seat
suspension to the cab floor.
2. Remove the seat suspension from the cab floor.
3. Position the new seat suspension onto the cab
floor.
4. Install the four capscrews that retain the seat
suspension to the cab floor.

Back Cushion Boot Replacement

Refer to the section Figure 21 for the following
Remove procedures.
Refer to the section Figure 21 for the following
procedures. 1. Use a small pry bar to remove the 22 plastic
plugs that retain the boot to the seat
1. Slide the seat assembly to the maximum suspension.
forward position.
2. Remove the boot.
2. If equipped, remove the headrest out of the two
guides. 3. Install the new boot.

3. Remove the two guides, located at the top side 4. Install the 22 plastic plugs that retain the boot
of the back cushion, that retain the back to the seat suspension.
cushion to the back pan.

24
0100 SRM 1390 Remove and Install

Suspension Scissor and Shock Absorber Replacement

Remove
NOTE: Replacement instructions for the air seat
and mechanical seat are similar.
STEP 1.
Remove the seat from the suspension. Refer to
Seat.

STEP 2.
Remove the seat suspension from the cab. Refer
to the section Seat Suspension Replacement.

STEP 3.
Remove the boot. Refer to Boot Replacement.

STEP 4.
Position the suspension on a workbench with
the lower housing facing upward.

STEP 5.
For air seats remove the retaining screws for
the air bladder.

STEP 6.
Using a 9/16” Allen wrench, remove the lower
housing pivot shaft nut.

25
Remove and Install 0100 SRM 1390

STEP 7.
Remove the pivot shaft.

STEP 8.
For mechanical seats: Lift the lower housing
and place the suspension scissor in the highest
raised position.

STEP 9.
For mechanical seats: Lift the rear of the lower
housing while sliding the lower housing
forward to disengage the height adjustment
rollers from the roller channels of the lower
housing.

26
0100 SRM 1390 Remove and Install

STEP 10.
Rotate the rear of the lower housing clockwise
to disengage the front suspension scissor rollers
from the roller channels of the lower housing.

STEP 11.
Remove the lower housing from the suspension.

STEP 12.
For mechanical seats: Remove the tether belts
from the suspension scissor lower pivot tubes.

STEP 13.
Using a 9/16” Allen wrench, remove the upper
housing pivot shaft nut.

27
Remove and Install 0100 SRM 1390

STEP 14.
Remove the pivot shaft.

STEP 15.
Remove the weight indicator tension spring
from the suspension scissor to avoid damage to
the weight indicator tension spring.

STEP 16.
Lift the suspension scissor while sliding the
suspension scissor forward to disengage the
front suspension scissor rollers from the roller
channels of the upper housing.

STEP 17.
For both types: Remove the suspension scissor
from the upper housing and place the
suspension scissor on one side. For air seats:
Remove the bladder.

28
0100 SRM 1390 Remove and Install

STEP 18.
Remove the tether belts from the suspension
scissor upper pivot tubes.

STEP 19.
Remove the rear bearing tubes from the
suspension scissor.

STEP 20.
Remove the front suspension scissor rollers
from the suspension scissor.

STEP 21.
Remove the push-on PAL nut that retains the
upper shock absorber bearing to the suspension
scissor.

29
Remove and Install 0100 SRM 1390

STEP 22.
Slide the shock absorber and the shock
absorber bearings out of the suspension scissor.

Install
STEP 1.
Install a new upper shock absorber bearing
onto the suspension scissor and slide the shock
absorber onto the suspension scissor.

STEP 2.
Install the new lower shock absorber bearing
into the shock absorber and onto the
suspension scissor.

30
0100 SRM 1390 Remove and Install

STEP 3.
Install a new push-on PAL nut to retain the
shock absorber to the suspension scissor.

STEP 4.
Use a hollow punch and a mallet to push the
push-on PAL nut until the push-on PAL nut
contacts the upper shock absorber bearing.

STEP 5.
Install the front suspension scissor rollers onto
the suspension scissor and apply MoS2 grease
on the rollers.

31
Remove and Install 0100 SRM 1390

STEP 6.
Install the rear bearing tubes to the suspension
scissor.

STEP 7.
For mechanical seats: Place the tether belts
over the suspension scissor upper pivot tubes.
For air seats: Install the bladder.

CAUTION
Make sure the front suspension scissor rollers are
positioned completely within the roller channels
or damage may occur.

STEP 8.
Position the front suspension scissor rollers into
the roller channels of the upper housing and
align the bearing shaft tubes of the suspension
scissor with the upper housing holes.

32
0100 SRM 1390 Remove and Install

STEP 9.
Install the weight indicator tension spring on
the suspension scissor.

NOTE: The pivot shaft must be aligned so the flat surface of the pivot shaft head faces the upper housing.
This alignment prevents the pivot shaft from rotating when the pivot shaft is installed.

STEP 10.
Apply a coat of MoS2 grease on the pivot shaft
and install the pivot shaft. Make sure the flat
surface of the pivot shaft head faces the upper
housing.

STEP 11.
For mechanical seats: Install the pivot shaft
nut and tighten to
38 to 56 N•m (28 to 41 lbf ft).

33
Remove and Install 0100 SRM 1390

STEP 12.
For mechanical seats: Position the height
adjustment mechanism so the suspension
scissor is in the lowest position.

STEP 13.
For mechanical seats: Place the tether belts
over the suspension scissor lower pivot tubes.

STEP 14.
Lift the suspension scissor to the highest raised
position.

STEP 15.
Use a wooden block [approximate length
110 mm (4.33 in.)] to keep the suspension
scissor in the highest raised position.

34
0100 SRM 1390 Remove and Install

CAUTION
The pivot shaft must be aligned so the flat surface
of the pivot shaft head faces the upper housing.
This alignment prevents the pivot shaft from
rotating when the pivot shaft is installed.

STEP 16.
Rotate the lower housing counterclockwise and
position the front suspension scissor rollers of
the suspension scissor into the roller channels
of the lower housing.

STEP 17.
Remove the wooden block and place the height
adjustment rollers in the roller channels of the
lower housing. Place the wooden block back
into position.

STEP 18.
Align the bearing shaft tubes of the suspension
scissor with the lower housing holes.

NOTE: The pivot shaft must be aligned so the flat surface of the pivot shaft head faces the lower housing.
This alignment prevents the pivot shaft from rotating when the pivot shaft is installed.

35
Remove and Install 0100 SRM 1390

STEP 19.
Apply a coat of MoS2 grease on the pivot shaft
and install the pivot shaft. Make sure the flat
surface of the pivot shaft head faces the lower
housing.

STEP 20.
Install the pivot shaft nut and tighten to
38 to 56 N•m (28 to 41 lbf ft).

STEP 21.
Remove the wooden block from the suspension.

STEP 22.
For air seats: Install the retaining screws for
the air bladder.

36
0100 SRM 1390 Remove and Install

STEP 23.
Install the boot. Refer to the section Boot
Replacement.

STEP 24.
Install the seat suspension in the cab. Refer to
Seat Suspension Replacement.

STEP 25.
Install the seat. Refer to the section Seat.

Compressor

Remove
STEP 1.
Remove the seat from the suspension. Refer to
Seat.

STEP 2.
Remove the seat suspension from the cab. Refer
to the section Seat Suspension Replacement.

STEP 3.
Remove the boot. Refer to Boot Replacement.

STEP 4.
Using a 1/16" Allen wrench, remove the air
control knob.

37
Remove and Install 0100 SRM 1390

STEP 5.
Remove the nut and lockwasher that retain the
air valve to the upper housing and withdraw
the air valve into the suspension.

STEP 6.
Using a 9/16" Allen wrench, remove the upper
housing pivot shaft nut.

STEP 7.
Remove the pivot shaft.

38
0100 SRM 1390 Remove and Install

STEP 8.
Lift the rear of the upper housing while sliding
the housing forward to disengage the front
rollers from the roller channels and remove the
upper housing.

STEP 9.
Use a wooden block (approximate dimensions of
45 x 25 x 100 mm (1.77 x 0.98 x 3.94 in.) to
chock the front roller bar of the suspension.

STEP 10.
Deflate the suspension to remove all air in the
pneumatic system.

39
Remove and Install 0100 SRM 1390

STEP 11.
Remove the tie wrap that retains the air valve
electrical wire harness and tube to the
suspension.

STEP 12.
Disconnect the orange electrical wire connector
from the air valve body.

STEP 13.
Disconnect the compressor black electrical wire
connector from the suspension harness at the
rear of the compressor assembly.

40
0100 SRM 1390 Remove and Install

STEP 14.
Unscrew (counterclockwise) the plastic tube
retaining nut from the output port of the
compressor. Remove the nut and O-ring from
the tube and discard.

STEP 15.
Remove and retain the two screws that retain
the compressor and bracket to the suspension
scissor. Remove the compressor and bracket
from the suspension.

STEP 16.
Note the orientation of the compressor in the
bracket. Remove the compressor from the
bracket.

41
Remove and Install 0100 SRM 1390

Install
STEP 1.
Place the new compressor into the bracket as
shown.

STEP 2.
Position the compressor and bracket into the
suspension and make sure the black electrical
wire is routed toward the rear of the seat and
the orange electrical wire is routed forward
toward the air valve.

42
0100 SRM 1390 Remove and Install

STEP 3.
Align the compressor bracket with the
suspension mounting holes and install the two
retaining screws. Remove the protective cap
from the compressor.

STEP 4.
Trim the tube that enters the compressor port
past the grooved/necked area created by the old
O-ring. If the tube is damaged or kinked,
replace the entire length of the tube and use
the original tube as a guide.

43
Remove and Install 0100 SRM 1390

STEP 5.
Install a new plastic nut and O-ring on the tube
as shown.

CAUTION
DO NOT crossthread or overtighten the plastic
nut, as damage can occur.

STEP 6.
Insert the tube into the compressor port and
slide the plastic nut and O-ring up to the
compressor and tighten (clockwise) the nut.
Make sure while tightening the nut that the
tube remains fully inserted into the compressor
port. Tighten the plastic nut until the face of
the nut is flush with the body of the compressor
as shown.

STEP 7.
Connect the compressor black electrical wire
connector to the black electrical wire connector
of the suspension harness.

44
0100 SRM 1390 Remove and Install

STEP 8.
Route the orange electrical wire to the air valve
and attach it to the air valve. Make sure the
wires are routed without knots or kinks.

STEP 9.
Install a new tie wrap to retain the electrical
wire harness and tube to the suspension.

STEP 10.
Power up the suspension and inflate the system
for approximately 45 seconds. Use a leak
detection spray or weak soapy water to check
for leaks from the air system. Remove the
wooden chock block from the suspension.

45
Remove and Install 0100 SRM 1390

STEP 11.
Position the front suspension scissor rollers into
the roller channels of the upper housing and
lower the upper housing onto the rear bearing
shaft tubes of the suspension scissor.

STEP 12.
Apply a coat of MoS2 grease on the pivot shaft
and install the pivot shaft.

STEP 13.
Install the pivot shaft nut and tighten to
38 to 56 N•m (28 to 41 lbf ft).

46
0100 SRM 1390 Remove and Install

STEP 14.
Insert the air valve through the upper housing.
Install the lockwasher and nut. Tighten the nut
to 10 to 18 N•m (88 to 159 lbf in).

STEP 15.
Using a 1/16" Allen wrench, install the air
control knob.

STEP 16.
Install the boot. Refer to the section Boot
Replacement.

STEP 17.
Install the seat suspension in the cab. Refer to
the section Seat Suspension Replacement.

STEP 18.
Install the seat on the suspension. Refer to the
section Seat.

47
Remove and Install 0100 SRM 1390

POWER ASSIST ARMREST

Release Cable
Remove
1. Raise the power assist armrest.

2. Loosen the two adjustment nuts that retain the

cable to the armrest. See Figure 22.

3. Disconnect the cable from the armrest and slide

the cable out of the slot in the armrest. See
Figure 22.

4. Disconnect the cable at the rod end of the gas

spring and slide the cable out of the slot.

5. Remove the cable from the power assist

armrest through the front side of the power
assist armrest.

Install
1. Install the cable through the power assist
armrest from the front side of the power assist
armrest.

2. Connect the cable at the rod end of the gas

spring.

3. Connect the cable to the armrest. See

Figure 22.

Adjust the cable length with the two nuts to 1. LEVER

4. 2. ROD END
obtain a free lever movement of 1.5 to 2.0 mm 3. LOCK NUT
before the gas spring will unlock. 4. MOUNTING CAPSCREW
5. ARMREST
5. Tighten the two nuts that retain the cable to 6. CABLE
the armrest. See Figure 22. 7. GAS SPRING
8. WASHER
9. ARMREST FRAME
6. Lower the power assist armrest. 10. NUT

Figure 22. Power Assist Armrest

Gas Spring
Remove
1. Raise the power assist armrest, and make sure
the gas spring has reached its maximum
extended length.

2. Disconnect the cable from the rod end of the

gas spring.

48
0100 SRM 1390 Remove and Install

3. Support the power assist armrest and remove Install

the bottom-mounting capscrew and washer
that retain the gas spring rod to the armrest 1. Connect the four electrical connectors to the
frame. joystick.

4. Manually lower the power assist armrest. 2. Position the joystick in the power assist
armrest with the electric cable pointing to the
5. Remove the top-mounting capscrew and washer right.
that retain the gas spring to the armrest frame.
3. Turn the joystick 90° clockwise.
6. Remove the gas spring.
4. Reroute the electrical cables and electrical
connectors inside the power assist armrest.
Install
1. Make sure that the gas spring has reached its 5. Install the four joystick screws to retain the
maximum extended length. joystick to the power assist armrest.

2. Position the gas spring. 6. Place the cover with the joystick label in
position on the power assist armrest. Install
3. Install the top-mounting capscrew and washer the four screws to retain the cover to the power
to retain the gas spring to the armrest frame. assist armrest.

4. Manually raise the power assist armrest. 7. Make sure the joystick functions properly.

5. Support the power assist armrest and install

the bottom-mounting capscrew and washer to
retain the gas spring to the armrest frame.

6. Connect and adjust the cable to the rod end of

the gas spring.

Joystick
Remove
1. Remove the four screws that retain the cover
with the joystick label to the power assist
armrest. See Figure 23.

2. Remove the cover from the power assist

armrest.
1. COVER SCREWS
3. Remove the four joystick screws that retain the 2. COVER
joystick to the power assist armrest. 3. JOYSTICK SCREWS
4. JOYSTICK
4. Partially raise the joystick until it is possible to 5. JOYSTICK ROTATION
turn the joystick 90° counterclockwise with the
Figure 23. Joystick Removal
electric cable inside the power assist armrest.

5. Completely remove the joystick from the power Electrical Levers

assist armrest. Remove
6. Tag and disconnect the four electrical NOTE: For lift trucks with hydraulic control levers,
connectors from the joystick. the remove and replace instructions are shown in
the model specific Hydraulic System SRM .

49
Remove and Install 0100 SRM 1390

1. Remove the four screws that retain the cover

with the levers to the power assist armrest. See
Figure 24.

NOTE: Most connectors are equipped with symbol

labels for identification.
2. If necessary, tag the electrical connector(s) for
identification.

3. Disconnect the electrical connector(s) from the

lever(s).

4. Remove the two screws that retain the lever to

the cover.

5. Remove the lever from the underside of the

cover.

Install
1. Install the lever from the underside to the 1. COVER
2. COVER SCREWS
cover. 3. LEVER SCREWS
4. LEVER
2. Install the two screws to retain the lever to the
cover. Figure 24. Levers Removal

3. Connect the electrical connector(s) to the Armrest Rocker Switches

lever(s).
Remove
4. Install the four screws that retain the cover
NOTE: If a failed switch is to be replaced by a new
with the levers to the power assist armrest.
one, use a screw driver to force the failed switch out
of the panel. The switch may suffer additional
5. Calibrate the lever. See the model specific
damage beyond repair. Remove the electrical
Hydraulic System SRM .
connector from the failed switch and connect it to
the replacement switch. Install the switch by
pressing it into the opening in the panel until the
holding clips of the switch are seated.
1. Remove six screws that retain the bottom plate
and lower the plate.

2. Press the holding clips on the switches and

push the rocker switch out of the armrest.

3. Disconnect the electrical connector.

Install
1. Connect the electrical connector to the rocker
switch.

2. Install the switch by pressing it into the

opening of the panel until the holding clips of
switch are seated.

50
0100 SRM 1390 Remove and Install

3. Install the bottom plate using six retaining 4. Remove the four screws that retain the fuse
screws. panel cover at the right side of the instrument
panel and remove the cover to gain access to
Armrest Top Cover the underside of the instrument panel. See
Figure 25.
Remove
1. Remove the joystick or lever cover. Refer to the 5. Remove the key switch by sliding the key
section Joystick or the section Electrical switch downward out of the hole to the inside of
Levers. the instrument panel top console.

2. Remove all rocker switches. Refer to the section 6. Disconnect the electrical connector from the
Armrest Rocker Switches. key switch.

3. Remove the six screws at the underside of the Install

armrest frame that retain the armrest top 1. Connect the electrical connector to the key
cover to the armrest frame. switch.
4. Remove the eight screws that retain the 2. Install the key switch by sliding the key switch
armrest top cover to the armrest plate. upward into the hole to the outside of the
instrument panel top console.
5. Remove the armrest top cover from the armrest
plate. 3. Position the key switch correctly into the hole
in the instrument panel top console.
Install
1. Position the armrest top cover on the armrest 4. Install the nut to retain the key switch to the
plate. instrument panel top console.

2. Install the eight screws to retain the armrest 5. Make sure that the key switch functions
top cover to the armrest plate. correctly.

3. Install the six screws at the underside of the 6. Position the fuse panel cover to the right side of
armrest frame to retain the armrest top cover the instrument panel and install the four
to the armrest frame. retaining screws. See Figure 25.

4. Install the rocker switches. Refer to the section

Armrest Rocker Switches.

5. Install the joystick or lever cover. Refer to the

section Joystick or the section Electrical
Levers.

INSTRUMENT PANEL
Key Switch
Remove
1. Switch the key to the OFF position.

2. Remove the key from the key switch.

3. Remove the nut that retains the key switch to

the instrument panel top console.

51
Remove and Install 0100 SRM 1390

3. Push the 12V power socket through the

instrument panel top console from the inside to
the outside.

Install
1. Install the 12V power socket to the instrument
panel top console from the outside to the inside
until the 12V power socket is secured to the
instrument panel top console. See Figure 26.

2. Connect the electrical connector to the 12V

power socket.

3. Position the fuse panel cover to the right side of

the instrument panel and install the four
retaining screws.

Electric-Operated Heat Control and Air

Recirculation Control (Airco Only)

1. SCREWS 2. COVER
Remove
1. Remove the four screws that retain the fuse
Figure 25. Fuse Panel and Cover Location panel cover to the right side of the instrument
panel and remove the cover to gain access to
12V Power Socket the underside of the instrument panel. See
Figure 25.
Remove
1. Remove the four screws that retain the fuse 2. Disconnect the electrical connector from the
panel cover to the right side of the instrument potentiometer at the inside of the instrument
panel and remove the cover to gain access to panel box.
the underside of the instrument panel. See
Figure 26. 3. Remove the air recirculation knob at the
instrument panel top console. See Figure 26.
2. Disconnect the electrical connector from the
12V power socket.

52
0100 SRM 1390 Remove and Install

1. KEY SWITCH 8. HEATER SWITCH COVER

2. POWER SOCKET 12V 9. ROCKER SWITCHES
3. KEY SWITCH COVER 10. PARKING BRAKE SWITCH COVER
4. FAN SPEED KNOB 11. PARKING BRAKE SWITCH
5. HEAT CONTROL KNOB 12. INSTRUMENT PANEL TOP CONSOLE
6. AIR RECIRCULATION KNOB (OPTIONAL) 13. INDICATOR DISPLAY
7. AIR CONDITIONING SWITCH (OPTIONAL)

Figure 26. Switch Locations

4. Remove the nut that retains the potentiometer
to the instrument panel top console.
5. Remove the potentiometer by sliding it
downward out of the hole to the inside of the
instrument panel top console.
Install
1. Install the potentiometer by sliding it upward
into the hole to the inside of the instrument
panel top console.
2. Install the nut that retains the potentiometer
to the instrument panel top console.
3. Install the air recirculation knob at the
instrument panel top console. See Figure 26.
4. Connect the electrical connector to the
potentiometer at the inside of the instrument
panel box.
5. Position the fuse panel cover to the right side of
the instrument panel and install the four
retaining screws. See Figure 25.
Cable-Operated Heater Control (Heater
Only)
Remove
1. Remove the four screws that retain the fuse
panel cover to the right side of the instrument
panel and remove the cover to gain access to
the underside of the instrument panel. See
Figure 25.
2. Remove the heat control knob at the
instrument panel top console. See Figure 26.
3. Remove the nut that retains the heat rotary
control assembly to the instrument panel top
console.

53
Remove and Install
4. Remove the heat rotary control assembly from
the underside of the instrument panel top
console.
5. Remove the cable clip and unlatch the inner
cable from the rotary control.
Install
1. Pull the inner cable to make sure the water
valve has reached its end position.
2. Turn the rotary control to the extended (full
hot) position.
3. Position and latch the inner cable to the heat
rotary control and install the cable clip.
4. Install the heat rotary control assembly from
the underside of the instrument panel top
console.
5. Install the nut to retain the heat rotary control
assembly to the instrument panel top console.
6. Install the heat control knob at the instrument
panel top console.
7. Position the fuse panel cover to the right side of
the instrument panel and install the four
retaining screws. See Figure 25.
Air Conditioning Switch Replacement
1. Remove the four screws that retain the fuse
panel cover to the right side of the instrument
panel and remove the cover to gain access to
the underside of the instrument panel. See
Figure 25.
2. Tag and disconnect the three electrical wires
from the air conditioning switch.
3. Remove the air conditioning switch by pressing
the two clips together and pushing the air
conditioning switch from the inside to the
outside. See Figure 26.
4. Install the new air conditioning switch by
pushing the air conditioning switch from the
outside to the inside until the two clips are
latched. See Figure 26.
5. Connect the three wires to the air conditioning
switch.
54
0100 SRM 1390
6. Position the fuse panel cover to the right side of
the instrument panel and install the four
retaining screws. See Figure 25.
Instrument Panel Rocker Switches
Replacement
1. Remove the four screws that retain the fuse
panel cover to the right side of the instrument
panel and remove the cover to gain access to
the underside of the instrument panel. See
Figure 25.
NOTE: Most connectors are equipped with symbol
labels for identification.
2. If necessary, tag the connector for
identification.
3. Disconnect the connector from the rocker
switch by pressing the clip at the connector.
4. Remove the rocker switch by pressing the two
clips together and pushing the rocker switch
from the inside to the outside. See Figure 26.
5. Install the new rocker switch by pushing the
rocker switch from the outside to the inside
until the two clips are latched. See Figure 26.
6. Connect the connector to the rocker switch.
7. Position the fuse panel cover to the right side of
the instrument panel and install the four
retaining screws. See Figure 25.
Parking Brake Switch
Remove
1. Remove the four screws that retain the parking
brake switch cover to the instrument panel top
console and remove the cover. See Figure 26.
2. Remove the tie wrap that connects the top and
bottom rubber boots to each other, which
together cover the electrical connector.
3. Remove the bottom rubber boot from the
electrical connector to gain access to the
electrical connector.
4. Disconnect the electrical connector by turning
the clip to one side.
0100 SRM 1390 Remove and Install

5. Remove the nut that retains the parking brake

switch to the parking brake switch cover.

6. Remove the parking brake switch from the

parking brake switch cover.

Install
1. Position the parking brake switch in the
parking brake switch cover.

2. Install the nut to retain the parking brake

switch to the parking brake switch cover.

3. Connect the electrical connector to the parking 1. INDICATOR DISPLAY CLIP

brake switch until the clip is securely latched.
4. Install the bottom rubber boot over the
electrical connector.
5. Place the top rubber boot over the bottom
rubber boot and tighten using a tie wrap.
6. Make sure the parking brake switch functions
correctly.
Figure 27. Indicator Display Removal
4. Install the new indicator display by pushing
the indicator display from the outside to the
inside until the two clips are latched.
5. Connect the electrical connector to the
indicator display at the inside of the
instrument panel box.

7. Position the parking brake switch cover to the 6. Position the fuse panel cover to the right side of
instrument panel top console and install the the instrument panel and install the four
four retaining screws. retaining screws. See Figure 25.

Indicator Display Replacement Instrument Panel Top Console

1. Remove the four screws that retain the fuse Remove
panel cover to the right side of the instrument
1. Remove the key switch cover and key switch.
panel and remove the cover to gain access to
Refer to the section Key Switch.
the underside of the instrument panel. See
Figure 25.
2. Remove the heater switch cover and switches.
See Figure 26. Refer to the section Electric-
2. Disconnect the electrical connector from the
Operated Heat Control and Air Recirculation
indicator display at the inside of the
Control (Airco Only) and the section Air
instrument panel box.
Conditioning Switch Replacement.
3. Remove the indicator display by pressing the
3. Remove the parking brake switch cover and
two clips together and pushing the indicator
parking brake switch. Refer to the section
display from the inside to the outside. See
Parking Brake Switch.
Figure 27.
4. Disconnect the electrical connector to the
instrument panel inside the instrument panel
box.

5. Remove the five screws that retain the

instrument panel top console to the cab, and
remove the instrument panel top console.

55
Remove and Install 0100 SRM 1390

Install 6. Make sure the switches function correctly.

1. Position the instrument panel top console to
STEERING WHEEL AND COLUMN
the cab and install the five retaining screws.
ASSEMBLY
2. Connect the electrical connector to the Steering Wheel and Horn
instrument panel inside the instrument panel
box. Remove
3. Install the parking brake switch and cover.
Refer to the section Parking Brake Switch. CAUTION
To prevent electrical arcs when removing the
4. Install the heater switch cover and switches. cover, disconnect the battery ground cable.
Refer to the section Electric-Operated Heat
Control and Air Recirculation Control (Airco 1. Disconnect the battery ground cable.
Only) and the section Air Conditioning Switch
Replacement. 2. Remove the horn button from the steering
wheel. See Figure 28.
5. Install the key switch and cover. Refer to the
section Key Switch.

56
0100 SRM 1390 Remove and Install

Figure 28. Steering Wheel and Steering Column Assembly

57
Remove and Install 0100 SRM 1390

Legend for Figure 28.

1. SCREW 11. UPPER LEFT-HAND STEERING COLUMN COVER

2. WASHER 12. UPPER RIGHT-HAND STEERING COLUMN
3. SCREW COVER
4. WASHER 13. LOWER LEFT-HAND STEERING COLUMN COVER
5. SOCKET 14. LOWER RIGHT-HAND STEERING COLUMN
6. HORN BUTTON COVER
7. SPINNER KNOB 15. STEERING COLUMN ASSEMBLY
8. STEERING WHEEL 16. BOOT
9. WIRE HARNESS 17. MAIN WARNING LIGHTS
10. TOP STEERING COLUMN COVER 18. STEERING CONTROL UNIT (UNDER CAB
FLOOR)
19. ADJUSTMENT HANDLE
20. CAPSCREW AND SPRING (LOCATION)

3. Disconnect the electrical wire from the horn

switch to the horn button. CAUTION
Use caution when removing the steering control
4. Remove the large nut and remove the steering unit or damage may occur.
wheel from the steering column.
5. Remove the four capscrews that retain the
Install steering control unit to the cab. See Figure 29.
1. Install the steering wheel and the large nut
onto the steering column. See Figure 28.
Tighten the nut to
35 to 45 N•m (26 to 33 lbf ft).

2. Connect the electrical wire from the horn

switch to the horn button.

3. Install the horn button onto the steering wheel.

4. Connect the battery ground cable.

Steering Column Assembly

Remove
1. Turn the battery disconnect switch to the OFF
position.

2. Remove the screws that retain the lower left-

hand and right-hand steering column covers to
the steering column. See Figure 28.

3. Tilt/raise the cab until it locks in the partially

open position. Refer to the section Tilting the
Cab.

4. Disconnect the steering column electrical

connector located under the cab. See the Cab,
Remove section of the model specific Frame
manual.

58
0100 SRM 1390 Remove and Install

1. CAPSCREW (STEERING COLUMN TO

BRACKET)
2. NUT (STEERING COLUMN TO CAB FLOOR)

Figure 30. Steering Column

8. Lower the cab until it is in the fully lowered

and latched position. Refer to the section
Tilting the Cab.

9. Remove the two capscrews that retain the

steering column to the bracket. See Figure 30.

10. Remove the steering column. Push the

grommet out of the hole and slide the connector
1. OPERATOR'S CAB through the hole in the cab floor.
2. STEERING CONTROL UNIT
3. WASHER Install
4. CAPSCREW
1. Slide the connector through the hole in the cab
Figure 29. Steering Control Unit, View Under floor and push the grommet into the hole.
Operator's Cab
2. Position the steering column to the cab floor
6. Place the steering control unit with the and Install the two capscrews to retain the
hydraulic hoses attached in the engine steering column to the bracket. See Figure 30.
compartment.
3. Tilt/raise the cab until it locks in the partially
7. Remove the two capscrews and nuts that retain open position. Refer to the section Tilting the
the steering column to the cab floor. See Cab.
Figure 30.
4. Install the two capscrews and nuts to retain the
steering column to the cab floor.

CAUTION
DO NOT force the steering control unit onto the
steering column shaft, as damage can occur.

59
Remove and Install 0100 SRM 1390

5. Place the steering control unit in position Main Warning Lights

under the cab while aligning the steering
column shaft with the slot in the steering
control unit.
6. Install the four capscrews and washers that
retain the steering control unit to the underside
of the operator’s cab.
7. Connect the steering column electrical
connector positioned under the cab. See the
Cab, Remove section of the model specific
Frame manual.
8. Lower the cab to the fully lowered and latched
position. Refer to the section Tilting the Cab.
9. Position the lower left-hand and right-hand
steering column covers and install the screws
to retain the covers. See Figure 28.
10. Turn the battery disconnect switch to the ON
position.
11. Check for correct operation.
Adjustment Handle
Remove
NOTE: The main warning lights are part of the top
steering column cover. When the main warning
lights must be replaced, the complete top steering
column cover must be replaced.
1. Remove the steering wheel. Refer to the section
Steering Wheel and Horn.
2. Remove the six screws and washers that retain
the top steering column cover to the upper left-
hand and right-hand steering column covers.
See Figure 28.
3. Tag and disconnect the two wires from the
main warning lights inside the top steering
column cover by loosening the two screws.
4. Remove the top steering column cover from the
steering column.
Install
1. Position the top steering column cover on the
steering column.

Remove 2. Connect the two wires to the main warning

1. Loosen the capscrew and spring that retain the
adjustment handle to the adjustment
mechanism. See Figure 28.
3.
2. Turn the adjustment handle counterclockwise
to loosen and remove the adjustment
mechanism from the steering column.
lights inside the top steering column cover and
tighten the two screws.
Position the top steering column cover to the
upper left-hand and right-hand steering
column covers and install the six retaining
screws and washers.

3. Remove the capscrew and spring that retain 4. Install the steering wheel. Refer to the section
the adjustment handle to the adjustment Steering Wheel and Horn.
mechanism.
Shift Lever
Install Remove
1. Position the adjustment handle and install the 1. Remove the steering wheel. Refer to the section
capscrew and spring to retain the adjustment Steering Wheel and Horn.
handle to the adjustment mechanism. Hand
tighten the capscrew at this time. 2. Remove the six screws and washers that retain
the top steering column cover to the upper left-
2. Turn the adjustment handle clockwise to hand and right-hand steering column covers.
install the adjustment mechanism to the See Figure 28.
steering column.
3. Remove the upper steering column cover from
3. Tighten the capscrew and spring that retain the steering column.
the adjustment handle to the adjustment
mechanism.

60
0100 SRM 1390 Remove and Install

4. Remove the two screws that retain the shift 4. Install the top steering column cover to the
lever to the steering column and remove the steering column. Refer to the section Steering
shift lever. Column Assembly.

5. Disconnect the electrical connector from the 5. Install the steering wheel. Refer to the section
shift lever. Steering Wheel and Horn.

Install 6. Make sure the turn signal lever functions

correctly.
1. Connect the electrical connector to the shift
lever.
WINDOW WIPERS
2. Position the shift lever to the steering column Window Wiper Assembly Replacement
and install the two retaining screws.
Remove
3. Install the six screws and washers that retain NOTE: Three window wiper motor assemblies are
the top steering column cover to the upper left- installed in the cab. The front window has a single-
hand and right-hand steering column covers. arm, parallelogram-type window wiper motor
system that creates a large wiping surface area. The
4. Install the steering wheel. Refer to the section
optional front window can be equipped with an H-
Steering Wheel and Horn.
wiper, which creates a wider view capacity. The
wiper motor is mounted under the cab so it does not
5. Make sure the shift lever functions correctly.
obstruct visibility. The top window and rear window
are equipped with a window wiper motor assembly
Turn Signal Lever that has one wiper arm with a wiper blade. A
Remove washer system is directly connected to the front and
top wipers. A washer nozzle is installed to the rear
1. Remove the steering wheel. Refer to the section cab frame to provide window washer fluid to the
Steering Wheel and Horn. rear window.
2. Remove the top steering column cover from the 1. Mark the position of the window wiper
steering column. Refer to the section Steering assembly on the window.
Column Assembly.
2. Disconnect the black washer hose from the
3. Remove the two screws and wire that retain connection adapter, if applicable.
the turn signal lever to the steering column.
3. Lift the cover. See Figure 31.
4. Remove the turn signal lever.
4. Remove the nut and washer.
5. Tag and disconnect the three wires connected
to the turn signal lever by loosening the three 5. Remove the window wiper assembly from the
screws. shaft and window.

Install Install
1. Connect the three wires to the turn signal lever NOTE: Make sure the window wiper assembly is
and tighten the three screws. properly positioned to provide optimal coverage of
the window.
2. Position the turn signal lever to the steering
column. 1. Position the window wiper assembly on the
window and shaft.
3. Install the two screws and wire that retain the
turn signal lever to the steering column. 2. Install and tighten the nut and washer.

3. Close the cover.

61
Remove and Install 0100 SRM 1390

4. Connect the washer hose, if applicable. 4. Connect the electrical connector to the wiper
motor.

5. Lower the cab to the fully lowered and latched

position. Refer to the section Tilting the Cab.

1. COVER
2. COVER OPENED
3. NUT WITH WASHER

Figure 31. Wiper Assembly

1. WIPER MOTOR ARM
Window Wiper Motor Replacement 2. CAPSCREW
3. WIPER MOTOR ASSEMBLY
Front Window Wiper Motor 4. WIPER MOTOR ELECTRICAL CONNECTOR
Remove Figure 32. Front Window Wiper Motor Assembly
1. Mark the wiper position.
Rear Window Wiper Motor Assembly
2. Tilt/raise the cab to the partially open position.
Refer to the section Tilting the Cab. Remove
3. Disconnect the electrical connector from the 1. Disconnect battery ground cable.
wiper motor. See Figure 32.
2. Remove the wiper assembly. Refer to the
4. Remove the capscrew on the wiper motor arm section Window Wiper Assembly Replacement.
and remove the wiper motor arm.
3. Remove the cover from the wiper motor
5. Remove the three capscrews that retain the assembly.
wiper motor to the underside of the cab.
4. Disconnect the wiper motor electrical
6. Remove the wiper motor assembly. connector. See Figure 33.

5. Remove the two nuts and washers that retain

Install the wiper motor assembly to the cab.
1. Position the wiper motor assembly to the
underside of the cab. 6. Remove the wiper motor assembly.

2. Install the three capscrews to retain the wiper Install

motor to the underside of the cab.
1. Position the wiper motor assembly to the cab.
3. Install the wiper motor arm and tighten the
2. Install the two washers and nuts to retain the
capscrew on the wiper motor arm.
wiper motor assembly to the cab.

62
0100 SRM 1390 Remove and Install

3. Connect the wiper motor electrical connector. 3. Connect the wiper motor electrical connector.

4. Install the cover on the wiper motor assembly. 4. Install the wiper assembly. Refer to the section
Window Wiper Assembly Replacement.
5. Install the wiper assembly. Refer to the section
Figure 33 5. Install the radio console. Refer to the section
Radio Console.
6. Connect battery ground cable.
6. Connect battery ground cable.

WINDOW WASHER SYSTEM

Window Washer Reservoir and Pumps
Remove
1. If installed, remove the training seat.

2. Remove the four capscrews and washers that

retain the cover to the right rear corner of the
cab and remove the cover.

3. Loosen the hose clamp that retains the fill hose

to the reservoir.

4. Disconnect the fill hose from the reservoir.

1. WIPER MOTOR CONNECTOR
2. NUTS AND WASHERS
5. Tilt/raise the cab to the partially open position.
Figure 33. Rear Wiper Motor Assembly Refer to the section Tilting the Cab.

6. Tag and disconnect the electrical connectors

Top Window Wiper Motor Assembly
from the washer motor and pumps.
Remove
NOTE: The reservoir must be drained prior to
1. Disconnect battery ground cable. removal of reservoir and pumps.
2. Remove the radio console. Refer to the section
Radio Console. 7. Drain the washer reservoir.

3. Remove the wiper assembly. Refer to the 8. Remove the two capscrews that retain the two
section Window Wiper Assembly Replacement. brackets to the reservoir at the left underside of
the cab.
4. Disconnect the wiper motor electrical
connector. 9. Remove the two brackets.

5. Remove the two nuts and washers that retain 10. Remove the reservoir.
the wiper motor assembly to the cab.
11. Tag and disconnect the three window washer
6. Remove the wiper motor assembly. hoses from the washer motor and pumps.

Install 12. Remove the window washer pumps by pulling

them away from the rubber seal in the hole of
1. Position the wiper motor assembly to the cab. the reservoir. See Figure 34.

2. Install the two washers and nuts to retain the

wiper motor assembly to the cab.

63
Remove and Install 0100 SRM 1390

7. Lower the cab to the fully lowered and latched

position. Refer to the section Tilting the Cab.

8. Connect the fill hose to the reservoir.

9. Tighten the hose clamp to retain the fill hose to

the reservoir.

10. Position the cover to the right rear corner of the

cab and install the four retaining capscrews
and washers.

11. If necessary, install the training seat.

12. Fill the window washer reservoir as needed.

Window Washer Hoses

Hoses for Top and Rear Window
Remove

1. Remove the four screws that retain the fuse

panel cover to the right side of the instrument
panel and remove the cover. See Figure 25.

2. Remove the five screws and washers that

retain the cable cover located at the right rear
corner of the cab. See Figure 35.

1. FRONT WINDOW WASHER MOTOR AND PUMP

2. TOP WINDOW WASHER MOTOR AND PUMP
3. REAR WINDOW WASHER MOTOR AND PUMP

Figure 34. Washer Motors and Pumps

Install
1. Install the window washer pumps by pushing
them in the rubber seal in the hole of the
reservoir. See Figure 34.

2. Connect the three window washer hoses to the

washer motors and pumps.

3. Install the reservoir.

4. Position the two brackets.

5. Install the two capscrews to retain the two

brackets to the reservoir at the left underside of
the cab.

6. Connect the electrical connectors to the washer

motors and pumps.

64
0100 SRM 1390 Remove and Install

12. Disconnect the washer hose(s) from the

connection adapter located at the inside of the
heater.

13. Remove the three capscrews that retain the

heater to the cab and swing the heater down.

14. Disconnect the washer hose(s) from the

connection adapter located at the outside of the
heater.

15. Remove the washer hose(s) from inside of the

instrument panel box.

NOTE: Step 16, Step 17, and Step 18 are for the top
window washer hose only.
16. Disconnect the black washer hose from the
connection adapter, located at the top side of
the cab roof.

17. Disconnect the black washer hose from the

1. CABLE COVER window washer nozzle.
2. PROTECTION SEAL
3. SCREW
4. WASHER 18. Remove the black washer hose from the top
window washer wiper arm.
Figure 35. Cable Cover Removal
Install
3. Remove the cable cover and protection seal.
NOTE: Step 1, Step 2, and Step 3 are for the top
window washer hose only.
4. Remove the radio console to gain access to the
washer hose end. Refer to the section Radio 1. Position the black washer hose to the top
Console. window washer wiper arm.

5. Drain the washer reservoir.
6. Disconnect the washer hoses at the connection
adapters located behind the radio console.
7. Place the washer hoses inside the instrument
panel box.
8. Tilt/raise the cab to the fully open position.
Refer to the section Tilting the Cab.
9. Remove the tie wraps that retain the washer
hose(s) to the underside of the cab.
10. Disconnect the washer hose(s) from the window
washer motor(s) and pump(s).
11. Disconnect the washer hose ends that are
connected to the valve(s) and remove the
valve(s).
2. Connect the black washer hose to the window
washer nozzle.
3. Connect the black washer hose to the
connection adapter at the top side of the cab
roof.
4. Position the washer hose inside the instrument
panel box.
5. Connect the washer hose(s) to the connection
adapters located at the inside of the heater.
6. Swing the heater up and install the three
capscrews that retain the heater to the cab.
7. Connect the washer hose(s) to the connection
adapters located at the outside of the heater.

65
Remove and Install 0100 SRM 1390

8. Connect the washer hose ends to the valve(s). Install

Make sure that the valve(s) are positioned
correctly. 1. Position the nozzle and install the two screws
to retain the nozzle to the front window wiper
9. Connect the washer hose(s) to the window arm.
washer motor(s) and pump(s) at the reservoir.
2. Connect the window washer hose to the nozzle.
10. Install the tie wraps to retain the washer
hose(s) to the underside of the cab. 3. Install the front window wiper assembly. Refer
to the section Window Wiper Assembly
11. Lower the cab to the fully lowered and latched Replacement.
position. Refer to the section Tilting the Cab.
4. Make sure the nozzle functions correctly.
12. Position the washer hose(s), located inside the
instrument panel box, along the right rear Rear Window
corner to the connection adapters. Remove
13. Connect the washer hose(s) to the connection 1. Remove the radio console inside the cab. Refer
adapters located behind the radio console. to the section Radio Console.

14. Install the radio console. Refer to the section 2. Disconnect the window washer hose from the
Radio Console. nozzle.

15. Install the cable cover and protection seal at 3. Remove the nut that retains the nozzle to the
the right rear corner and install the five screws cab rear frame.
and washers. See Figure 35.
4. Remove the nozzle and rubber boot to the
16. Position the fuse panel cover to the right side of outside of the cab rear frame.
the instrument panel and install the four
retaining screws. See Figure 25. Install
1. Install the nozzle and rubber boot from the
17. Fill the reservoir with washer fluid.
outside to the cab rear frame.
18. Check for leaks.
2. Install the nut to retain the nozzle to the cab
rear frame.
WINDOW WASHER SPRAY NOZZLES
Front Window 3. Connect the window washer hose to the nozzle.

Remove 4. Make sure the nozzle functions correctly.

1. Remove the front window wiper assembly.
5. Install the radio console. Refer to the section
Refer to the section Window Wiper Assembly
Radio Console.
Replacement.

2. Disconnect the window washer hose from the Top Window

nozzle. Remove
3. Remove the two screws that retain the nozzle 1. Disconnect the window washer hose from the
to the front window wiper arm and remove the nozzle.
nozzle.
2. Remove the nozzle from the top window washer
wiper.

66
0100 SRM 1390 Remove and Install

Install Replacement windows that are not made of the

1. Install the nozzle to the top window washer
wiper.
2. Connect the window washer hose to the nozzle.
3. Make sure the nozzle functions correctly.
WINDOW REPLACEMENT
WARNING
All windows installed in the cab are made of
special glass. All replacement windows must be
made of the correct material and thickness.
correct material or thickness may cause the glass
to break easily when struck and may cause
personal injury.
NOTE: Before replacing any window, remove all
broken glass bits. Make sure replacement glass is
dry, clean, and free of grease.
The front, rear, and top windows are single units.
The front and rear windows are held in place by
rubber seals only. The top window is fastened by
roof clips. The door window and sliding window
assemblies are glued in. See Figure 36.

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Remove and Install 0100 SRM 1390

1. SLIDING WINDOW 6. DOOR

2. SEAL 7. SEAL
3. WINDOW EDGE PROTECTION SEAL 8. GLUED SEAL
4. UPPER WINDOW 9. LOWER WINDOW
5. GLUED SEAL 10. WINDOW EDGE PROTECTION SEAL

Figure 36. Doors/Glass Assemblies

68
0100 SRM 1390 Remove and Install

Front Window 4. Pull out the plastic thread toward the inside of
the cab. This will ensure that the slot of the
Remove window seal slides properly over the window
1. Remove the front window wiper assembly. frame.
Refer to the section Window Wiper Assembly
Replacement. 5. Press the window firmly into place.

2. Remove the string from the window seal. See 6. Insert the string.
Figure 37.
7. Install the front window wiper assembly. Refer
to the section Window Wiper Assembly
Replacement.

Rear Window
Remove
1. Remove the rear window wiper assembly. Refer
to the section Window Wiper Assembly
Replacement.

2. Remove the rear window wiper motor

assembly. See the section Rear Window Wiper
Motor Assembly.

3. Remove the string from the window seal. See

Figure 36.
1. FRONT WINDOW
2. WINDOW SEAL
3. CAB SIDE SLOT 4. Remove the rear window from the window seal.
4. STRING
5. PLASTIC THREAD (INSTALLATION TOOL) 5. Remove the window seal from around the
6. CAB FRAME window at the operator’s compartment opening.

Figure 37. Front Window Install

3. Remove the front window from the window
seal.
4. Remove the window seal from around the
window at the operator’s compartment opening.
Install
NOTE: Replace the window seal if the seal is
damaged.
1. Install the window seal around the window.
2. Insert a plastic thread (insulated electric wire)
approximately 3.0 mm (0.118 in.) in the slot of
the window seal (cab side slot).
NOTE: Replace the window seal if the seal is
damaged.
1. Install the window seal around the window.
2. Insert a plastic thread (insulated electric wire)
approximately 3.0 mm (0.118 in.) in the slot of
the window seal (cab side slot).
3. Position and press the window against the
operator’s compartment opening.
4. Pull the plastic thread out toward the inside of
the cab. This will ensure that the slot of the
window seal slides properly over the window
frame.

3. Position and press the window against the 5. Press the window firmly into place.
operator’s compartment opening.
6. Insert the string.

69
Remove and Install 0100 SRM 1390

7. Install the rear window wiper motor assembly. 2. Remove the five protecting caps, nuts, and
See the section Rear Window Wiper Motor washers from the window clip. See Figure 38.
Assembly.

8. Install the rear window wiper assembly. See

the section Window Wiper Assembly
Replacement.

Top Window
Remove
1. Remove the top window wiper assembly. Refer
to the section Window Wiper Assembly
Replacement.

1. PROTECTIVE CAP 6. TOP WINDOW

2. NUT 7. PROTECTIVE CAP
3. PLASTIC WASHER 8. NUT
4. ROOF CLIP 9. WASHER
5. ROOF CLIP COVER 10. WINDOW CLIP AND SEAL

Figure 38. Top Window

3. Remove the window clip and seal. 5. Remove the three roof clips and roof clip covers.

4. Remove the three protective caps, nuts, and 6. Remove the top window from the operator's
plastic washers that retain the roof clips to the compartment opening.
cab.

70
0100 SRM 1390 Remove and Install

Install 2. Remove the upper/lower window.

1. Clean the window opening and seal located 3. With a sharp knife, slice through the adhesive
under the window clip. line between the glued seal and the window
opening.
2. Install a new adhesive seal to the top window.
4. Remove the glued seal from the window
3. Position the top window onto the operator’s opening.
compartment opening. SeeFigure 38 .
5. Clean the window opening and the glued seal.
4. Position the window clip and seal over the
thread ends and install the five nuts and
Install
washers, hand tighten.
1. Apply a bead of adhesive to the window
5. Position the three roof clips and roof clip covers opening.
and install the plastic washers and nuts, hand
tighten. NOTE: Replace the glued seal if the seal is
damaged.
6. If necessary, carefully push the front side of the
2. Install the glued seal to the window opening.
top window until the seal touches the top
window. Tighten the three nuts of the three 3. Install the upper/lower window.
roof clips until the top window is evenly held in
the desired position. Repeat the same 4. Install the window edge protection seal.
procedure for the rear side of the top window
and the window clip. 5. Apply pressure to the window edge protection
seal and the window until the window is
7. Install the protective caps onto the nuts. seated.

8. Install the top window wiper assembly. Refer to Sliding Window and Sliding Tracks
the section Window Wiper Assembly
Replacement. Remove
1. Open the sliding window slightly to gain access
Door, Upper/Lower Window to the sliding tracks. See Figure 39.
Remove
1. Remove the window edge protection seal that
retains the window in the door frame. See
Figure 36.

71
Remove and Install 0100 SRM 1390

1. WINDOW SEAL 7. WINDOW SEAL

2. WINDOW STOPPER 8. WEATHER STRIP (PRE-ASSEMBLED)
3. WINDOW SEAL 9. FRONT SLIDING WINDOW (PRE-ASSEMBLED)
4. WINDOW STOPPER 10. SLIDING TRACKS
5. WINDOW SEAL 11. REAR SLIDING WINDOW (PRE-ASSEMBLED)
6. SLIDING WINDOW FRAME

Figure 39. Sliding Window Assembly

72
0100 SRM 1390 Remove and Install

2. Bend each end section of the window support
profile outward, to allow the sliding track to
move out of the window support profile. See
Figure 40.
5. Place a screwdriver behind the second sliding
track as shown in Figure 40, and slide the
sliding window to the other side to free the
second sliding track from underneath the
sliding window.

6. Remove the second sliding track.

7. Remove the sliding window, top side first, from

the window frame.

8. Remove the two capscrews that retain the

window latch assembly and remove the
assembly.

9. Slide the weather strip from the sliding

window.

Install
1. Position and install the weather strip to the
front sliding window using a rubber mallet.

2. Position the window latch assembly and install

the two retaining capscrews.

3. Position the sliding window, bottom side first,

in the window frame.

4. Clamp the two sliding tracks on the sliding

1. SLOT frame at the left-hand and right-hand side of
2. SLIDING WINDOW
3. WINDOW SUPPORT PROFILE the sliding window.
4. SCREWDRIVER LOCATION (REMOVAL)
5. INNER SLOT BEND LOCATION 5. Place a screwdriver behind the sliding track as
6. SLIDING TRACK show in Figure 40, and slide the sliding window
7. END SECTION over the sliding track.
8. SCREWDRIVER LOCATION (INSTALLATION)
6. Bend the end section to the inside of the sliding
Figure 40. Slot Location
window until it locks the sliding track.

7. Place a screwdriver behind the second sliding

CAUTION
Make sure the sliding window does not fall out
when the sliding tracks are removed. Take
precautions to keep the sliding window in place.
3. Place a screwdriver behind the sliding track as
shown in Figure 40, and slide the sliding
window away to free the sliding track from
underneath the sliding window.
4. Remove the sliding track.
track as shown in Figure 40, and slide the
sliding window over the second sliding track.
8. Bend the end section to the inside of the sliding
window.
Weather Strip Replacement
1. Slide the clamped weather strip from the
sliding window. See Figure 39.
2. Position and install the new weather strip to
the front sliding window using a rubber mallet.

73
Remove and Install 0100 SRM 1390

Window Stopper Replacement
1. Remove the window stopper. See Figure 39.
2. Apply instant glue to the window frame.
3. Install the window stopper and apply pressure
until the stopper is seated.
Window Seal Replacement
1. Remove the front and rear sliding windows.
Refer to the section Sliding Window and
Sliding Tracks.
2. Clean the bead at the door frame with a clean
lint-free cloth and Sika Coating Activator. The
waiting time after cleaning is a minimum of 10
minutes to a maximum of 2 hours.
3. Apply Sikaflex 260 in the shape of a triangular
bead on the remaining bead of adhesive at the
door frame. Make sure the height of the
triangular bead is
4 to 5 mm (0.157 to 0.197 in.). See Figure 41.

2. Remove the window seals. See Figure 39.

3. Apply instant glue to the sliding window frame.

4. Install the new window seals and apply

pressure until the seals are seated.

Sliding Window Frame

Remove
1. Separate the glued seal located at the upper
window from the sliding window frame. See
Figure 36.
NOTE: Do not completely remove the existing bead
of adhesive. Leave a remaining layer of adhesive on
the door frame.
2. Remove the sliding window frame by slicing
through the adhesive line one piece at a time
from the inside with a sharp knife.
3. Trim the existing bead of adhesive down to
approximately 1 to 2 mm (0.039 to 0.078 in.) at
the door frame.
Install
1. ADHESIVE
2. REMAINDER OF ORIGINAL BEAD
Figure 41. Silicon Bead
NOTE: The clamps that hold the sliding window
frame to the door frame should remain in place for a
minimum of 12 hours.
4. Use clamps for correct positioning, and install
the sliding window frame to the door frame.
Make sure there is a gap between the sliding
window frame and the door frame to allow
water to drain.
5. Remove excess (uncured) adhesive with Sika
Remover 208 immediately. Do not use solvents.

NOTE: The installation of the sliding window frame 6. Use a roller to position the removed glued seal
requires the use of a glue kit, Hyster P/N 1674109 . located at the upper window to the sliding
The glue kit consists of the following: window frame and upper window.
• Sika Coating Activator
7. Make sure the sliding window frame is firmly
• Sika Remover 208
mounted in the door frame.
• Sikaflex 260
1. Clean the bond area of the sliding window
frame with a clean lint-free cloth and Sika
Coating Activator. The waiting time after
cleaning is a minimum of 10 minutes to a
maximum of 2 hours.

74
0100 SRM 1390
FLOOR MAT
Front Floor Mat
Remove
1. Tilt/raise the cab to the fully open position.
Refer to the section Tilting the Cab.
2. Remove the foam from around the throttle
pedal.
3. If the lift truck is equipped with a
MONOTROL® pedal, disconnect the electrical
connector.
4. Remove the capscrew, spring washer, and nut
that retain the accelerator pedal or
MONOTROL® pedal to the cab frame.
5. Separate the coupling from the accelerator
pedal or MONOTROL® pedal.
6. Lower the cab to the fully lowered and latched
position. Refer to the section Tilting the Cab.
7. Remove the accelerator pedal or MONOTROL®
pedal.
8. Remove the steering column. Refer to the
section Steering Column Assembly.
9. Remove the split pin and washer from the rod
located behind the inching pedal.
10. Disconnect the rod from the inching pedal.
11. Remove the two capscrews, washers, and nuts
that retain the inching pedal to the bracket at
the cab floor.
12. Remove the two capscrews, washers, and nuts
that retain the brake pedal to the bracket at
the cab floor.
13. Remove the inching and brake pedal assembly.
14. Remove the front floor mat.
Install
1. Install the front floor mat.
2. Position the inching and brake pedal assembly
between the brackets on the floor of the cab.
Remove and Install
3. Install the two capscrews, washers, and nuts to
retain the brake pedal to the bracket, at the cab
floor.
4. Install the two capscrews to retain the inching
pedal to the bracket, at the cab floor.
5. Connect the rod to the inching pedal.
6. Install the washer and split pin to the rod
located behind the inching pedal.
7. Install the steering column. Refer to the section
Steering Column Assembly.
8. Position the accelerator pedal or MONOTROL®
pedal, if the lift truck is equipped with a
MONOTROL® pedal.
9. Tilt/raise the cab to the fully open position.
Refer to the section Tilting the Cab.
10. Attach the coupling to the accelerator pedal or
MONOTROL® pedal.
11. Install the capscrew, spring washer, and nut to
retain the accelerator pedal or MONOTROL®
pedal to the cab frame.
12. If the lift truck is equipped with a
MONOTROL® pedal, connect the electrical
connector to the MONOTROL® pedal.
13. Install the foam around the throttle pedal.
14. Lower the cab until it is in the fully lowered
and latched position. Refer to the section
Tilting the Cab.
15. Check if any inching and brake pedal
adjustment is required and adjust as needed.
Refer to the section Dry Brake.
16. Check and adjust the accelerator pedal. Refer
to the section Accelerator Pedal and Sensor.
Rear Floor Mat
Remove
1. Open the left-hand and right-hand cab doors
until the doors are securely latched.
75
Remove and Install 0100 SRM 1390

2. If equipped with a storage box, remove the two 7. If equipped, install the training seat located at
screws located at the left side of the seat that the left rear corner of the cab. Refer to the
retain the storage box to the cab floor. section Seat Assembly.

3. If equipped, remove the training seat, located 8. If equipped with a storage box, install the two
at the left rear corner of the cab. Refer to the screws located at the left side of the seat that
section Seat Assembly. retain the storage box to the cab floor.

4. Remove the four capscrews located at the left RADIO CONSOLE

rear corner that retain the cover to the cab.
Remove
5. Remove the seat suspension. Refer to the 1. Remove the top sunshade. Refer to the section
section Seat Assembly. Sunshade Replacement.
NOTE: If equipped with a storage box, the 2. Remove the rear sunshade. Refer to the section
capscrews are located inside the storage box behind Sunshade Replacement.
the operator's seat.
6. Remove the four capscrews that retain the 3. Remove the cover from the rear window wiper
storage box behind the operator’s seat to the motor.
cab floor.
4. Remove the capscrew that retains the bracket
7. Remove the four screws located at the right to the rear window wiper motor.
side of the rear floor mat that retain the strip
to the cab floor. 5. Remove the capscrew that retains the bracket
to the radio console and remove the bracket.
8. If equipped, remove the three air nozzles.
6. Remove the six capscrews and washers at the
9. Remove the rear floor mat. front side of the radio console. See Figure 42.

Install
1. Install the rear floor mat.

2. If equipped, install the three air nozzles.

3. Install the four screws located at the right side

of the rear floor mat to retain the strip to the
cab floor.

NOTE: If equipped with a storage box, the

capscrews are located inside the storage box behind
the operator's seat.
4. Install the four capscrews that retain the
storage box behind the operator’s seat to the
cab floor.

5. Install the seat suspension. Refer to the section 1. RADIO CONSOLE

Seat Assembly. 2. CAPSCREW
3. WASHER
6. Install the four capscrews located at the left Figure 42. Radio Console
rear corner to retain the cover to the cab.
7. Remove the four capscrews and washers at the
underside of the radio console.

76
0100 SRM 1390 Remove and Install

8. Disconnect the two electrical connectors of the 3. Position the new air duct to the front side of the
interior lights at the left-hand and right-hand cab.
side of the radio console.
4. Install the six capscrews located at the left-
9. Remove the radio console from the rear side of hand and right-hand underside of the air duct.
the interior cab roof.
Remove Rear
Install 1. Open the left- and right cab door completely.
1. Position the radio console to rear side of the
interior cab roof. 2. Remove the rear floor mat. See the section
Floor Mat.
2. Connect the two electrical connectors of the
interior lights at the left-hand and right-hand 3. Remove the five screws that retain the cable
side of the radio console. cover at the right rear corner of the operator's
cab.
3. Install the four capscrews and washers at the
underside of the radio console. See Figure 42. 4. Remove the four screws that retain the fuse
panel cover at the right side of the instrument
4. Install the six capscrews and washers at the panel. See Figure 43.
front side of the radio console.

5. Position the bracket between the radio console

and the rear window wiper motor.

6. Install the capscrew to retain the bracket to the

radio console.

7. Install the capscrew to retain the bracket to the

rear window wiper motor.

8. Install the cover to the rear window wiper

motor.

9. Install the rear sunshade. Refer to the section

Sunshade Replacement.

10. Install the top sunshade. Refer to the section

Sunshade Replacement.

AIR DUCT REPLACEMENT

Remove Front 1. RETAINING SCREWS
1. Remove the six capscrews located at the left- 2. FUSE PANEL COVER
hand and right-hand underside of the air duct.
Figure 43. Fuse Panel and Cover Location

5. Remove the six screws retaining the cover for

CAUTION the key switch at the instrument panel top
Use caution when removing and installing the air console.
duct to avoid damage to the steering column and
the front window. 6. Remove the key switch, see the section
Instrument Panel.
2. Remove the air duct from the front side of the
cab.

77
Remove and Install
7. Remove the six screws that retain the cover to
the instrument panel top console and lift the
cover partially out the instrument panel top
console.
8. Remove the four screws that retain the cover
with the heater switches to the instrument
panel top console and lift the cover partially out
the instrument panel top console.
9. Remove the four screws that retain the cover
with the parking brake to the instrument panel
top console and lift the cover partially out the
instrument panel top console.
10. Remove the five screws that retain the
instrument panel top console to the instrument
panel.
CAUTION
Use caution not to damage the electrical wires of
the instrument panel switches.
11. Partially remove the instrument panel top
console to gain access to the heater hose clamp
and the screw at the underside of the air duct.
12. Remove the three screws located at the
underside that retain the instrument panel
side console to the cab.
13. Remove the instrument panel side console.
14. Remove the heater hose clamp from the
underside of the air duct.
NOTE: Screws can be partially hidden by the foam
cover underneath the air duct.
15. Remove the four screws located at the
underside of the air duct.
16. Remove the four screws located at the topside
of the air duct.
17. Remove the air duct.
Install
1. Position the air duct.
2. Install the four screws located at the topside of
the air duct.
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0100 SRM 1390
NOTE: The screw locations can be partially hidden
by the foam cover underneath the air duct.
3. Install the four screws located at the underside
of the air duct.
4. Install the heater hose clamp to the underside
of the air duct.
5. Position the instrument panel side console.
6. Install the three screws located at the
underside that retain the instrument panel
side console to the cab.
NOTE: Make sure the wires of the instrument
panel clear of any restrictions.
7. Carefully position the instrument panel top
console.
8. Install the five screws that retain the
instrument panel top console to the instrument
panel.
9. Position the cover with the parking brake and
install the four screws that retain the cover to
the instrument panel top console.
10. Position the cover with the heater switches and
install the four screws that retain the cover to
the instrument panel top console.
11. Position the cover to the instrument panel top
console and install the six screws that retain
the cover to the instrument panel top console.
12. Position the cover for the key switch and install
the six screws that retain the cover for the key
switch to the instrument panel top console.
13. Install the key switch, see the section
Instrument Panel.
14. Install the four screws that retain the fuse
panel cover at the right side of the instrument
panel.
15. Install the five screws that retain the cable
cover at the right rear corner of the operator's
cab.
16. Install the floor mat rear. See the section Floor
Mat.
0100 SRM 1390 Remove and Install

ACCESSORIES 2. Remove the handle.

Mirror Replacement 3. Remove the two capscrews at the left-hand and

NOTE: Mirrors are located at the top left-hand and right-hand side of the sunshade that retain the
right-hand front corner inside the cab. sunshade to the radio console.

1. Remove the nut behind the mirror that retains 4. Remove the sunshade.
the mirror to the cab frame.
5. Position the new sunshade.
2. Remove the mirror from the cab frame.
6. Install the two capscrews at the left-hand and
3. Position the new mirror to the cab frame. right-hand side of the sunshade to retain the
sunshade to the radio console.
4. Install the nut behind the mirror to retain the
mirror to the cab frame. 7. Position the handle to the sliding bar at the
rear window.
Sunshade Replacement
8. Install the two capscrews to retain the handle
Top with a bracket to the sliding bar.
NOTE: The top sunshade is located under the cab
roof and attached to the radio console. Map Light Replacement
1. Remove the two capscrews that retain the NOTE: The map light is attached to the frame in
handle with a bracket to the sliding bar at the the right rear corner of the cab.
roof.
1. Disconnect the wire connector located inside
the fuse panel.
2. Remove the handle.
2. Remove the two capscrews that retain the map
3. Remove the two capscrews at the left-hand and
light to the cab frame.
right-hand side of the sunshade that retain the
sunshade to the radio console.
3. Remove the map light from the cab frame.
4. Remove the sunshade.
4. Position the new map light to the cab frame.
5. Position the new sunshade.
5. Install the two capscrews to retain the map
light to the cab frame.
6. Install the two capscrews at the left-hand and
right-hand side of the sunshade to retain the
6. Connect the wire connector located inside the
sunshade to the radio console.
fuse panel.
7. Position the handle to the sliding bar at the
roof.
Interior Fan Replacement
NOTE: The interior fan is located at the right rear
8. Install the two capscrews to retain the handle corner inside the cab, and is attached to the frame.
with a bracket to the sliding bar.
1. Disconnect the wire connector from the fan.
Rear 2. Remove the four capscrews that retain the
NOTE: The rear sun shade is located at the rear interior fan to the cab frame.
window inside the cab and is attached to the radio
console. 3. Remove the interior fan from the cab frame.
1. Remove the two capscrews that retain the 4. Position the new interior fan to the cab frame.
handle with a bracket to the sliding bar at the
rear window. 5. Install the four capscrews to retain the interior
fan to the cab frame.

79
Checks and Adjustments
6. Connect the wire connector to the fan.
Training Seat
Field Installation
NOTE: The training seat is located at the left rear
corner of the cab and is attached to the cab floor and
the side frame of the cab.
NOTE: Two threaded holes in the cab floor are
covered by a rubber mat. Holes are partially
punched in the rubber mat to show the location of
the threaded holes and to create access to the
threaded holes in the cab floor.
1. Remove the rubber from the two partially
punched holes in the rubber mat to create
access to the threaded holes in the cab floor.
2. Position the training seat and install two
capscrews at the cab floor side and one
capscrew at the cab frame side.
Remove
1. Remove the two capscrews at the cab floor side
and one capscrew at the cab frame side.
2. Remove the training seat.
LABEL REPLACEMENT
WARNING
Labels that have WARNINGS or CAUTIONS must
be replaced if they are damaged. If a mast of a
different size or an accessory carriage is installed,
Checks and Adjustments
CHECK OIL LEVEL FOR CAB TILT
SYSTEM
CAUTION
When oil is added to the cab tilt system, place an
oil absorbing material around the fill cap before
lowering the cab. Excess oil may bleed out of the
relief valve, which is located in the fill cap.
NOTE: If the oil level is low, the cab will not tilt/
raise completely.
NOTE: If the cab is lowered, perform Step 1. If the
cab is raised, go to Step 2.
80
0100 SRM 1390
the capacity rating may change. Installing different
drive tires can change the capacity rating. See a
dealer for Hyster lift trucks for a replacement
nameplate. The nameplate information is a safety
item and must be correct for the equipment and
configuration of the lift truck.
1. Make sure the surface is dry and free of oil or
grease. DO NOT use solvent on new paint.
Clean the surface of old paint using cleaning
solvent.
2. Remove the paper from the back of the label.
Do not touch the adhesive surface.
3. Carefully position the label in the correct
position above the surface. The label cannot be
moved after it touches the surface. Place the
label on the surface. Make sure all of the air is
removed from under the label and the corners
and edges are tightly affixed.
See the Parts Manual for correct location and part
numbers of the labels.
1. Tilt/Raise the cab until it locks in the partially
open position. Refer to the section Tilting the
Cab.
2. Lower the cab until it locks in the partially
open position. Refer to the section Tilting the
Cab.
3. Place the pump lever connection in the fully
down position to create easy access to the fill
cap. See Figure 44.
0100 SRM 1390 Checks and Adjustments

DOOR STRIKER PIN ADJUSTMENT

1. Make sure the door hinges are correctly
installed.

2. Loosen the securing nut that retains the door

striker pin to the cab frame. See Figure 46.

1. FILL CAP
2. PUMP LEVER CONNECTION

Figure 44. Hand Pump

4. Remove the fill cap. See Figure 44.

5. Add hydraulic oil through the filler opening

until the level is within
30 to 35 mm (1.18 to 1.38 in.) of the top of the
reservoir. See Figure 45. For your lift truck,
refer to the appropriate Periodic Maintenance 1. CAB FRAME
SRM for the correct hydraulic oil specification. 2. SECURING NUT
3. DOOR STRIKER PIN

Figure 46. Door Striker Pin

3. Place the door striker pin in the expected

latching position.

4. Push and hold the release button and close the

door with normal force so that the door is
positioned correctly in the door opening of the
cab.

5. Open the door with the release button still

engaged.
Figure 45. Cab Tilt Label
6. Carefully tighten the securing nut that retains
6. Install the fill cap. See Figure 44. the door striker pin to the cab frame.

7. Tilt/raise the cab and make sure the maximum
tilted/raised (fully opened) position can be
reached. Refer to the section Tilting the Cab.
8. If necessary, repeat Step 1 through Step 7.
7. Close the door and make sure the door is
correctly seated against the door seals.
8. If necessary, repeat Step 1 through Step 7.

9. Lower the cab until it is in the fully lowered

position and completely latched. Refer to the
section Tilting the Cab.

81
Checks and Adjustments 0100 SRM 1390

BRAKE PEDAL ADJUSTMENT of a 1 mm. sized spacer, reduces the angle of

Dry Brake
Adjust the capscrew behind the pedal on the brake
pedal assembly to 5 to 10 mm (0.2 to 0.4 in.) travel
until the brake lights come ON. See Figure 47.
the brake pedal by 2 degrees, which moves the
brake pedal up.
Make sure that the brake pedal angle does not
exceed 140° when the brake pedal is pushed
down completely. If the angle exceeds 140°, the
coupling of the inching pedal may touch the
floor and prevent full engagement of the
brakes.

INCHING PEDAL ADJUSTMENT

NOTE: Inching pedal adjustment influences inching
sensor adjustment and inching sensor calibration.
After the inching pedal has been adjusted, always
correct inching sensor adjustment and inching
sensor calibration. Incorrect inching sensor
calibration triggers fault codes during operation.

1. Adjust the bolt behind the inching pedal on the

inching pedal assembly to the same plane with
the brake pedal adjustment bolt.

2. Adjust the adjustment bolt for the inching/

brake pedal coupling so that the inching pedal
has no free play. Both pedals should move
together when applying the inching pedal. An
additional spring installed under the inching
1. BRAKE PEDAL pedal allows for flexibility when adjusting the
2. INCHING PEDAL brake/inching overlap. See Figure 48.
3. PEDAL COUPLING ADJUSTMENT BOLT
4. PEDAL ADJUSTMENT BOLT

Figure 47. Brake and Inching Pedal Adjustment

Wet Brake
1. Adjust the cap screw behind the pedal on the
brake pedal assembly to let the roller have
contact with the cap screw on the valve and
there is no free travel.

2. Verify that the roller touches the center of the

cap screw on the brake valve. If sideways
adjustment is required, order and install the
latest narrow spaced roller and re-arrange the
washers at the sides of the roller.

3. Verify that the angle of the brake pedal does

not exceed 135°. To obtain a higher pedal
adjustment, install differently sized spacers
between brake valve and cabin floor. The total
size of the standard spacer is 10 mm. Removal

82
0100 SRM 1390
Figure 48. Brake Inching Pedal Adjustment
INCHING PEDAL SENSOR ADJUSTMENT
Sensor Adjustment Using Dana
Dashboard Software
NOTE: When the inching pedal is not activated
(pedal up position), the analog output of the inching
pedal sensor should be between 800 and 900 mV.
NOTE: When the inching pedal is fully depressed,
the analog output should be about 3.70 Volt.
NOTE: A slight preload of the potentiometer arm is
required to achieve the output voltage for the
inching pedal up position. Use the Dana Dashboard
software to check the output voltage.
1. Connect a laptop computer to the diagnostic
plug in the side console.
2. Turn the key switch to the ON position.
3. Select "Inching Pedal Calibration Mode".
4. Make sure the analog input of the inching
pedal sensor is between 800 and 900 mV.
5. If the analog input is not within specifications,
proceed as follows:
Checks and Adjustments
a. Tilt/raise the cab until the latch locks in the
partial open position. Refer to the section
Tilting the Cab.
b. Loosen the two inching pedal sensor
mounting capscrews. See Figure 49.
1. SENSOR MOUNTING CAPSCREW
2. INCHING PEDAL SENSOR
Figure 49. Sensor Adjustment
c. Rotate the inching pedal sensor in the
slotted holes underneath the inching pedal
until the output voltage of the released (up
position) inching pedal is between 800 and
900 mV.
d. Tighten the two sensor-mounting capscrews
and make sure the output voltage of the
inching pedal sensor is still between 800 and
900 mV, with the inching pedal in the up
position.
e. Check output voltage of the sensor with the
pedal fully depressed. Theoretically the
output voltage can be between 2.50 V and
4.00 V. A practical output value is 3.70 V.
f. Perform inching pedal calibration after the
sensor has been adjusted.
g. Lower the cab to the fully lowered and
latched position. Refer to the section Tilting
the Cab.
6. Turn the key switch to the OFF position.
83
Checks and Adjustments
7. Disconnect the laptop computer from the
diagnostic plug.
Sensor Adjustment using the APC200
Display
NOTE: This procedure does not require a laptop.
NOTE: Before calibrating the inching pedal sensor,
the inching pedal must be adjusted correctly. See
the section Brake Pedal Adjustment.
1. Press and hold the "S" button, and turn the key
switch to the ON position. During the first 15
seconds, the display will show:
2. Release the "S" button after 15 seconds when
the display shows:
3. Push the "M" button until the APC200 display
shows the analog input:
4. Push the "S" button three times. The display
will show 0.11, 1.28, 2.29, and a value. Pushing
the "S" button one more time changes the
display to 3.47. Releasing the "S" button shows
the value in Ohms for the inching pedal sensor
(for instance, "0.652"):
NOTE: The voltage reading of the inching pedal
sensor will be shown after a 1-2 second delay.
NOTE: The actual reading on the APC200 display
must be between 0.800 and 0.900, which represents
800 to 900mV.
5. Check the voltage reading of the inching pedal
sensor. The reading must be between 0.800 and
0.900.
84
0100 SRM 1390
6. If the reading is not within range, adjust the
inching pedal sensor until the reading is within
specifications.
7. Turn the key switch to the OFF position to
leave the APC200 test function group.
Sensor Adjustment for Trucks with ZF
Transmission
1. Connect a laptop, loaded with Testman
software, to the diagnostic connector which is
located in the side console.
2. Select Analog Inputs in Testman.
3. Verify Inch Sensor 1 (AU1 [V]) voltage for the
inching sensor is between 0.8-0.9V (800-900
mV).
4. If voltage is incorrect, proceed as follows:
Raise the Cab until the latch locks in the
partial open position.
Loosen the two mounting bolts of the inching
sensor.
Rotate the sensor in the slotted holes until
output voltage is between 0.8-0.9V (800-900
mV) in released pedal position.
Tighten the two mounting bolts and verify
output voltage is still correct.
INCHING PEDAL SENSOR CALIBRATION
Sensor Calibration using Dana Dashboard
Software
NOTE: When the inching pedal is not activated
(pedal up position), the analog output of the inching
pedal sensor should be between 800 and 900 mV.
When the inching pedal is fully depressed, the
analog output should be about 3.70 Volt.
1. Make sure the pedals and inching sensor have
been correctly adjusted.
2. Connect a laptop computer to the diagnostic
plug in the side console.
3. Turn the key switch to the ON position.
4. Use the "Automatic Calibration" mode of the
Dana Dashboard software.
0100 SRM 1390
5. Select the "Inching Pedal Calibration" mode of
the Dana Dashboard software and follow the
instructions.
6. The following two points must be calibrated
while the engine is running:
• Fully released pedal (800- 900 mV)
• Fully depressed pedal (2500-4000 mV). A
practical maximum value is 3700 mV.
7. Check the inching percentage of the
transmission by using the Dana Dashboard
software. When the pedal is released, the
inching percentage should be at 0%. If the
sensor has been adjusted, then the inching
percentage will deviate from 0%, requiring a
repeated Inching Pedal Calibration.
8. Turn the key switch to the OFF position.
9. Disconnect the laptop computer from the
diagnostic plug.
Sensor Calibration using APC200 Display
NOTE: This procedure does not require a laptop.
1. Press and hold the "S" button, and turn the key
switch to the ON position. During the first 15
seconds, the display will show:
2. Release the "S" button after 15 seconds when
the display shows:
3. Push the "M" button several times until the
APC200 display shows:
4. Push the "S" button once to start the inching
pedal sensor calibration. The APC200 display
will show:
Checks and Adjustments
5. Push the "S" button while in the pedal up
position. The APC200 display will show:
6. Fully depress the inching pedal and push the
"S" button again.
7. When the calibration has been completed, the
APC200 display will show:
NOTE: Calibration procedure must be repeated if
the ignition is turned back ON too early.
8. Turn the key switch to the OFF position to
save the calibration settings.
Observe the APC200 display and wait until all
segments no longer light up. When the display
remains OFF, new calibration has been
entered into the APC200 memory. The new
calibration settings will be lost if the key switch
is turned back ON too early.
Sensor Calibration for Trucks with ZF
Transmission
1. Park truck on level ground and apply the park
brake.
2. Make sure pedals and inch sensor have been
correctly adjusted.
3. Verify the Forward/Reverse lever is in
NEUTRAL.
4. Turn the ignition key in the OFF position.
5. Turn the transmission calibration switch in the
side console to the ON position (flip the switch
to the down position).
6. Be seated in the operator’s seat.
85
Checks and Adjustments 0100 SRM 1390

7. Turn the ignition key switch to the ON position

but DO NOT start the truck. The inch pedal
calibration mode is now active.

8. The LCD display shows: • tP_dn. Slowly press

the inch pedal all the way down to the end
position in 2 to 3 seconds and hold.

9. The LCD display shows: • tP_UP. Slowly

release the inch pedal in 2 to 3 seconds to the
completely released position.

10. When all values are within range, the LCD

display shows: • tPSEt, indicating inch pedal
calibration is finished. If inch pedal calibration
is not successful, the LCD display shows a fault
code. See SRM , Description for rectification.

11. After calibration is finished, switch OFF

ignition and turn the calibration switch OFF
(flip the switch to the up position).

86
 TECHNICAL PUBLICATIONS

0100 SRM 1390 12/18 (1/16)(12/15)(7/15)(9/14)(7/14)